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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2012

NASA's Space Launch System Advanced Booster Engineering Demonstration and Risk Reduction Efforts

The National Aeronautics and Space Administration (NASA) formally initiated the Space Launch System (SLS) development in September 2011, with the approval of the program s acquisition plan, which engages the current workforce and infrastructure to deliver an initial 70 metric ton (t) SLS capability in 2017, while using planned block upgrades to evolve to a full 130 t capability after 2021. A key component of the acquisition plan is a three-phased approach for the first stage boosters. The first phase is to complete the development of the Ares and Space Shuttle heritage 5-segment solid rocket boosters for initial exploration missions in 2017 and 2021. The second phase in the booster acquisition plan is the Advanced Booster Risk Reduction and/or Engineering Demonstration NASA Research Announcement (NRA), which was recently awarded after a full and open competition. The NRA was released to industry on February 9, 2012, and its stated intent was to reduce risks leading to an affordable Advanced Booster and to enable competition. The third and final phase will be a full and open competition for Design, Development, Test, and Evaluation (DDT&E) of the Advanced Boosters. There are no existing boosters that can meet the performance requirements for the 130 t class SLS. The expected thrust class of the Advanced Boosters is potentially double the current 5-segment solid rocket booster capability. These new boosters will enable the flexible path approach to space exploration beyond Earth orbit, opening up vast opportunities including near-Earth asteroids, Lagrange Points, and Mars. This evolved capability offers large volume for science missions and payloads, will be modular and flexible, and will be right-sized for mission requirements. NASA developed the Advanced Booster Engineering Demonstration and/or Risk Reduction NRA to seek industry participation in reducing risks leading to an affordable Advanced Booster that meets the SLS performance requirements. Demonstrations and/or risk reduction efforts were required to be related to a proposed booster concept directly applicable to fielding an Advanced Booster. This paper will discuss, for the first time publicly, the contract awards and how NASA intends to use the data from these efforts to prepare for the planned Advanced Booster DDT&E acquisition as the SLS Program moves forward with competitively procured affordable performance enhancements.

Crumbly, Christopher M.↗
NASA NTRS2012

NASA's Space Launch System Advanced Booster Engineering Demonstration and/or Risk Reduction Efforts

The National Aeronautics and Space Administration (NASA) formally initiated the Space Launch System (SLS) development in September 2011, with the approval of the program s acquisition plan, which engages the current workforce and infrastructure to deliver an initial 70 metric ton (t) SLS capability in 2017, while using planned block upgrades to evolve to a full 130 t capability after 2021. A key component of the acquisition plan is a three-phased approach for the first stage boosters. The first phase is to complete the development of the Ares and Space Shuttle heritage 5-segment solid rocket boosters (SRBs) for initial exploration missions in 2017 and 2021. The second phase in the booster acquisition plan is the Advanced Booster Risk Reduction and/or Engineering Demonstration NASA Research Announcement (NRA), which was recently awarded after a full and open competition. The NRA was released to industry on February 9, 2012, with a stated intent to reduce risks leading to an affordable advanced booster and to enable competition. The third and final phase will be a full and open competition for Design, Development, Test, and Evaluation (DDT&E) of the advanced boosters. There are no existing boosters that can meet the performance requirements for the 130 t class SLS. The expected thrust class of the advanced boosters is potentially double the current 5-segment solid rocket booster capability. These new boosters will enable the flexible path approach to space exploration beyond Earth orbit (BEO), opening up vast opportunities including near-Earth asteroids, Lagrange Points, and Mars. This evolved capability offers large volume for science missions and payloads, will be modular and flexible, and will be right-sized for mission requirements. NASA developed the Advanced Booster Engineering Demonstration and/or Risk Reduction NRA to seek industry participation in reducing risks leading to an affordable advanced booster that meets the SLS performance requirements. Demonstrations and/or risk reduction efforts were required to be related to a proposed booster concept directly applicable to fielding an advanced booster. This paper will discuss, for the first time publicly, the contract awards and how NASA intends to use the data from these efforts to prepare for the planned advanced booster DDT&E acquisition as the SLS Program moves forward with competitively procured affordable performance enhancements.

Crumbly, Christopher M.↗
NASA NTRS2016

NASA's SPACE LAUNCH SYSTEM: Development and Progress

NASA is embarked on a new era of space exploration that will lead to new capabilities, new destinations, and new discoveries by both human and robotic explorers. Today, the International Space Station (ISS) and robotic probes are yielding knowledge that will help make this exploration possible. NASA is developing both the Orion crew vehicle and the Space Launch System (SLS) (Figure 1), that will carry out a series of increasingly challenging missions leading to human exploration of Mars. This paper will discuss the development and progress on the SLS. The SLS architecture was designed to be safe, affordable, and sustainable. The current configuration is the result of literally thousands of trade studies involving cost, performance, mission requirements, and other metrics. The initial configuration of SLS, designated Block 1, will launch a minimum of 70 metric tons (mT) (154,324 pounds) into low Earth orbit - significantly greater capability than any current launch vehicle. It is designed to evolve to a capability of 130 mT (286,601 pounds) through the use of upgraded main engines, advanced boosters, and a new upper stage. With more payload mass and volume capability than any existing rocket, SLS offers mission planners larger payloads, faster trip times, simpler design, shorter design cycles, and greater opportunity for mission success. Since the program was officially created in fall 2011, it has made significant progress toward launch readiness in 2018. Every major element of SLS continued to make significant progress in 2015. Engineers fired Qualification Motor 1 (QM-1) in March 2015 to test the 5-segment motor, including new insulation, joint, and propellant grain designs. More than 70 major components of test article and flight hardware for the Core Stage have been manufactured. Seven test firings have been completed with an RS-25 engine under SLS operating conditions. The test article for the Interim Cryogenic Propulsion Stage (ICPS) has also been completed. Major work continues in 2016 as the program continues both flight and development RS-25 engine testing, begins welding test article and flight core stage tanks, completes stage adapter manufacturing, and test fires the second booster qualification motor. This paper will discuss the program's key accomplishments to date and the challenging work ahead for what will be the world's most capable launch vehicle.

Honeycutt, John↗
NASA NTRS2005

Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies

In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).

DeWitt, Kenneth↗
NASA NTRS1994

Analytical and experimental studies of impinging liquid jets

Impinging injectors are a common type of injector used in liquid propellant rocket engines and are typically used in engines where both propellants are injected as a liquid, e.g., engines using LOX/hydrocarbon and storable propellant combinations. The present research program is focused on providing the requisite fundamental understanding associated with impinging jet injectors for the development of an advanced a priori combustion stability design analysis capability. To date, a systematic study of the atomization characteristics of impinging liquid jets under cold-flow conditions have been completed. Effects of orifice diameter, impingement angle, pre-impingement length, orifice length-to-diameter ratio, fabrication procedure, jet flow condition and jet velocity under steady and oscillating, and atmospheric- and high-pressure environments have been investigated. Results of these experimental studies have been compared to current models of sheet breakup and drop formation. In addition, the research findings have been scrutinized to provide a fundamental explanation for a proven empirical correlation used in the design of stable impinging injector-based rocket engines.

Ryan, H. M.↗
NASA NTRS2011

Comprehensive Forced Response Analysis of J2X Turbine Bladed-Discs with 36- Degree Variation in CFD Loading

At NASA/MSFC, Structural Dynamics personnel continue to perform advanced analysis for the turbomachinery in the J2X Rocket Engine, which is under consideration for the new Space Launch System. One of the most challenging analyses in the program is predicting turbine blade structural capability. Resonance was predicted by modal analysis, so comprehensive forced response analyses using high fidelity cyclic symmetric finite element models were initiated as required. Analysis methodologies up to this point have assumed the flow field could be fully described by a sector, so the loading on every blade would be identical as it travelled through it. However, in the J2X the CFD flow field varied over the 360 deg of a revolution because of the flow speeds and tortuous axial path. MSFC therefore developed a complex procedure using Nastran Dmap's and Matlab scripts to apply this circumferentially varying loading onto the cyclically symmetric structural models to produce accurate dynamic stresses for every blade on the disk. This procedure is coupled with static, spin, and thermal loading to produce high cycle fatigue safety factors resulting in much more accurate analytical assessments of the blades.

Elrod, David↗
NASA NTRS2012

High-Pressure Systems Suppress Fires in Seconds

Much deserved attention is given to the feats of innovation that allow humans to live in space and robotic explorers to beam never-before-seen images back to Earth. In the background of these accomplishments is a technology that makes it all possible the rockets that propel NASA s space exploration efforts skyward. Marshall Space Flight Center has been at the heart of the Agency s rocketry and spacecraft propulsion efforts since its founding in 1960. Located at the Redstone Arsenal near Huntsville, Alabama, the Center has a legacy of success stretching back to the Saturn rockets that carried the Apollo astronauts into space. Even before Marshall was established, Redstone was the site of significant advances in American rocketry under the guidance of famous rocket engineer Werner Von Braun; these included the Juno I rocket that successfully carried the United States first satellite, Explorer 1, into orbit in 1958. And from the first orbital test flight of the Space Shuttle Columbia through the final flights of the shuttle program this year, these vehicles have been enabled by the solid rocket boosters, external tank, and orbiter main engines created at Marshall. Today, Marshall continues to host innovation in rocket and spacecraft propulsion at state-of-the-art facilities such as the Propulsion Research Laboratory. Like many of its past successes, some of the Center s current advancements are being made with the help of private industry partners. The efforts have led not only to new propulsion technologies, but to terrestrial benefits in a seemingly unrelated field in this case, firefighting.

Source record↗
NASA NTRS2007

NASA Hypersonic Propulsion: Overview of Progress from 1995 to 2005

Hypersonic propulsion work supported by the United States National Aeronautics and Space Administration had a primary focus on Space Transportation during the period from 1995 to 2005. The framework for these advances was established by policy and pursued with substantial funding. Many noteworthy advances were made, highlighted by the pinnacle flights of the X-43. This paper reviews and summarizes the programs and accomplishments of this era. The accomplishments are compared to the goals and objectives to lend an overarching perspective to what was achieved. At least dating back to the early days of the Space Shuttle program, NASA has had the objective of reducing the cost of access to space and concurrently improving safety and reliability. National Space Transportation Policy in 1994 coupled with a base of prior programs such as the National Aerospace Plane and the need to look beyond the Space Shuttle program set the stage for NASA to pursue Space Transportation Advances. Programs defined to pursue the advances represented a broad approach addressing classical rocket propulsion as well as airbreathing propulsion in various combinations and forms. The resulting portfolio of activities included systems analysis and design studies, discipline research and technology, component technology development, propulsion system ground test demonstration and flight demonstration. The types of propulsion systems that were pursued by these programs included classical rocket engines, "aerospike" rocket engines, high performance rocket engines, scram jets, rocket based combined cycles, and turbine based combined cycles. Vehicle architectures included single and two stage vehicles. Either single types of propulsion systems or combinations of the basic propulsion types were applied to both single and two stage vehicle design concepts. Some of the propulsion system design concepts were built and tested at full scale, large scale and small scale. Many flight demonstrators were conceptually defined, fewer designed and some built and one flown to demonstrate several technical advancements including propulsion. The X-43 flights were a culmination of these efforts for airbreathing propulsion. During the course of that period, there was a balance of funding and emphasis toward rocket propulsion but still very substantial airbreathing propulsion effort. The broad objectives of these programs were to both advance and test the state of the art so as to provide a basis for options to be pursued for broad space transportation needs, most importantly focused on crew carrying capability. NASA cooperated with the Department of Defense in planning and implementation of these programs to make efficient use of objectives and capabilities where appropriate. Much of the work was conducted in industry and academia as well as Government laboratories. Many test articles and data-bases now exist as a result of this work. At the conclusion of the period, the body of work made it clear that continued research and technology development was warranted, because although not ready for a NASA system development decision, results continued to support the promise of air-breathing propulsion for access to space.

Cikanek, Harry A., III↗
NASA NTRS2016

Affordable Development and Demonstration of a Small Nuclear Thermal Rocket (NTR) Engine and Stage: How Small Is Big Enough?

The Nuclear Thermal Rocket (NTR) derives its energy from fission of uranium-235 atoms contained within fuel elements that comprise the engine's reactor core. It generates high thrust and has a specific impulse potential of approximately 900 specific impulse - a 100 percent increase over today's best chemical rockets. The Nuclear Thermal Propulsion (NTP) project, funded by NASA's Advanced Exploration Systems (AES) program, includes five key task activities: (1) Recapture, demonstration, and validation of heritage graphite composite (GC) fuel (selected as the Lead Fuel option); (2) Engine Conceptual Design; (3) Operating Requirements Definition; (4) Identification of Affordable Options for Ground Testing; and (5) Formulation of an Affordable Development Strategy. During fiscal year (FY) 2014, a preliminary Design Development Test and Evaluation (DDT&E) plan and schedule for NTP development was outlined by the NASA Glenn Research Center (GRC), Department of Energy (DOE) and industry that involved significant system-level demonstration projects that included Ground Technology Demonstration (GTD) tests at the Nevada National Security Site (NNSS), followed by a Flight Technology Demonstration (FTD) mission. To reduce cost for the GTD tests and FTD mission, small NTR engines, in either the 7.5 or 16.5 kilopound-force thrust class, were considered. Both engine options used GC fuel and a common fuel element (FE) design. The small approximately 7.5 kilopound-force criticality-limited engine produces approximately157 thermal megawatts and its core is configured with parallel rows of hexagonal-shaped FEs and tie tubes (TTs) with a FE to TT ratio of approximately 1:1. The larger approximately 16.5 kilopound-force Small Nuclear Rocket Engine (SNRE), developed by Los Alamos National Laboratory (LANL) at the end of the Rover program, produces approximately 367 thermal megawatts and has a FE to TT ratio of approximately 2:1. Although both engines use a common 35-inch (approximately 89-centimeters) -long FE, the SNRE's larger diameter core contains approximately 300 more FEs needed to produce an additional 210 thermal megawatts of power. To reduce the cost of the FTD mission, a simple one-burn lunar flyby mission was considered to reduce the liquid hydrogen (LH2) propellant loading, the stage size and complexity. Use of existing and flight proven liquid rocket and stage hardware (e.g., from the RL10B-2 engine and Delta Cryogenic Second Stage) was also maximized to further aid affordability. This paper examines the pros and cons of using these two small engine options, including their potential to support future human exploration missions to the Moon, near Earth asteroids (NEA), and Mars, and recommends a preferred size. It also provides a preliminary assessment of the key activities, development options, and schedule required to affordably build, ground test and fly a small NTR engine and stage within a 10-year timeframe.

Spacecraft design↗
NASA NTRS1988

Space Software for Automotive Design

John Thousand of Wolverine Western Corp. put his aerospace group to work on an unfamiliar job, designing a brake drum using computer design techniques. Computer design involves creation of a mathematical model of a product and analyzing its effectiveness in simulated operation. Technique enables study of performance and structural behavior of a number of different designs before settling on a final configuration. Wolverine employees attacked a traditional brake drum problem, the sudden buildup of heat during fast and repeated braking. Part of brake drum not confined tends to change its shape under combination of heat, physical pressure and rotational forces, a condition known as bellmouthing. Since bellmouthing is a major factor in braking effectiveness, a solution of problem would be a major advance in automotive engineering. A former NASA employee, now a Wolverine employee, knew of a series of NASA computer programs ideally suited to confronting bellmouthing. Originally developed as aids to rocket engine nozzle design, it's capable of analyzing problems generated in a rocket engine or automotive brake drum by heat, expansion, pressure and rotational forces. Use of these computer programs led to new brake drum concept featuring a more durable axle, and heat transfer ribs, or fins, on hub of drum.

Source record↗
NASA NTRS2021

Electrochemical System Recovers Hydrogen and Helium for Rocket Engine Tests

SKYRE, Inc. received NASA SBIR and STTR funding to develop electrochemical systems for recovering and compressing gases. SKYRE has worked with Stennis Space Center to advance the company’s Hydrogen Recovery System (HRS) for supplying compressed hydrogen and helium, which are required for rocket engine testing. Through funding from the NASA Civilian Commercialization Readiness Pilot Program, and with business training from the NASA SBIR/STTR I-Corps program, SKYRE has commercialized its technology into two product lines, valuing SBIR/STTR-related revenue at $25 million.

SBIR/STTR↗
NASA NTRS1973

Linear rocket engine design-fabrication-testing

A new rocket engine concept that is presently being evaluated offers significant performance, cost, and configurational advantages. The Linear Rocket Engine System, (LRES) combines the unique performance and operational advantages of the aerospike nozzle with the configuration versatility of low cost modular combustors, which results in a high-performance rocket engine package designed specifically for use in advanced configuration vehicles. This paper describes the design, fabrication, and testing of the LRES concept to evaluate its potential for vehicle integration. The program was conducted under the sponsorship of NASA's Marshall Space Flight Center.

Fuller, P. N.↗
NASA NTRS2004

Advanced Methods for Aircraft Engine Thrust and Noise Benefits: Nozzle-Inlet Flow Analysis

In this project on the first stage (2000-Ol), we continued to develop the previous joint research between the Fluid Mechanics and Acoustics Laboratory (FM&AL) at Hampton University (HU) and the Jet Noise Team (JNT) at the NASA Langley Research Center (NASA LaRC). At the second stage (2001-03), FM&AL team concentrated its efforts on solving of problems of interest to Glenn Research Center (NASA GRC), especially in the field of propulsion system enhancement. The NASA GRC R&D Directorate and LaRC Hyper-X Program specialists in a hypersonic technology jointly with the FM&AL staff conducted research on a wide region of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines. The last year the Hampton University School of Engineering & Technology was awarded the NASA grant, for creation of the Aeropropulsion Center, and the FM&AL is a key team of the project fulfillment responsible for research in Aeropropulsion and Acoustics (Pillar I). This work is supported by joint research between the NASA GRC/ FM&AL and the Institute of Mechanics at Moscow State University (IMMSU) in Russia under a CRDF grant. The main areas of current scientific interest of the FM&AL include an investigation of the proposed and patented advanced methods for aircraft engine thrust and noise benefits. This is the main subject of our other projects, of which one is presented. The last year we concentrated our efforts to analyze three main problems: (a) new effective methods fuel injection into the flow stream in air-breathing engines; (b) new re-circulation method for mixing, heat transfer and combustion enhancement in propulsion systems and domestic industry application; (c) covexity flow The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines (see, for example, Figures 4). The FM&AL Team uses analytical methods, numerical simulations and experimental tests at the Hampton University campus, NASA and IM/MSU.

Morgan, Morris H., III↗
NASA NTRS2016

NASA's Space Launch System: Development and Progress

NASA is embarked on a new era of space exploration that will lead to new capabilities, new destinations, and new discoveries by both human and robotic explorers. Today, the International Space Station (ISS), supported by NASA's commercial partners, and robotic probes, are yielding knowledge that will help make this exploration possible. NASA is developing both the Orion crew vehicle and the Space Launch System (SLS) that will carry out a series of increasingly challenging missions that will eventually lead to human exploration of Mars. This paper will discuss the development and progress on the SLS. The SLS architecture was designed to be safe, affordable, and sustainable. The current configuration is the result of literally thousands of trade studies involving cost, performance, mission requirements, and other metrics. The initial configuration of SLS, designated Block 1, will launch a minimum of 70 metric tons (t) into low Earth orbit - significantly greater capability than any current launch vehicle. It is designed to evolve to a capability of 130 t through the use of upgraded main engines, advanced boosters, and a new upper stage. With more payload mass and volume capability than any rocket in history, SLS offers mission planners larger payloads, faster trip times, simpler design, shorter design cycles, and greater opportunity for mission success. Since the program was officially created in fall 2011, it has made significant progress toward first launch readiness of the Block 1 vehicle in 2018. Every major element of SLS continued to make significant progress in 2015. The Boosters element fired Qualification Motor 1 (QM-1) in March 2015, to test the 5-segment motor, including new insulation, joint, and propellant grain designs. The Stages element marked the completion of more than 70 major components of test article and flight core stage tanks. The Liquid Engines element conducted seven test firings of an RS-25 engine under SLS conditions. The Spacecraft/Payload Integration and Evolution element marked completion of the upper stage test article. Major work continues in 2016 as the program continues both flight and development RS-25 engine testing, begins welding test article and flight core stage tanks, completes stage adapter manufacturing, and test fires the second booster qualification motor. This paper will discuss the program's key accomplishments to date and the challenging work ahead for what will be the world's most capable launch vehicle.

Honeycutt, John↗
NASA NTRS1998

NASA Advanced Fuels Program

NASA with the USAF Research Laboratory and it's industry partners, has been conducting planning and research into advanced fuels. This work is sponsored under the NASA Advanced Space Transportation Program (ASTP). The current research focus is on Alternative Hydrocarbon fuels, Monopropellants, and Solid Cryogens for storing atoms of Hydrogen, Boron, Carbon, and Aluminum. Alternative hydrocarbons that are under consideration are bi cyclo propylidene, spiro pentane, and tri propargyl amine. These three fuels have been identified as initial candidates to increase the specific impulse of hydrocarbon fueled rockets by 10-15 seconds over 02/RP-1. Formulation of these propellants is proceeding this year, and rocket engine testing is planned for the near future. Monopropellant investigations are focused on dinitramine based fuels, and potential collaborations with the US Navy. The dinitramine fuel work is being conducted under an Small Business Innovation research (SBIR) contract with the team of Orbital Technologies Corp. (Madison, WI) and SRI (Menlo Park, CA). This work may lead to a high density, high specific impulse monopropellants that can simplify the operations for launch vehicles and spacecraft. Solid Cryogens are being considered to store atoms of Hydrogen, Boron, Carbon, and Aluminum. Stored atom propellants are potentially the highest specific impulse chemical rockets that may be practical. These fuels are composed of atoms, stored in solid cryogenic particles, suspended in a cryogenic liquid or gel. The fuel would be fed to a rocket engine as a slurry or gelled cryogenic liquid with the suspended particles with the trapped atoms. Testing is planned to demonstrate the formation of the particles, and then characterize the slurry flows. Rocket propellant and propulsion technology improvements can be used to reduce the development time and operational costs of new space vehicle programs. Advanced propellant technologies can make the space vehicles safer, more operable, and better performing. Five technology areas are described: Monopropellants, Alternative Hydrocarbons, Gelled Hydrogen, Metallized Gelled Propellants, and High Energy Density Materials. The benefits of these propellants for future vehicles are outlined using mission study results and the technologies are briefly discussed.

Palaszewski, Bryan↗
NASA NTRS1995

Advanced Small Rocket Chambers. Option 3: 110 1Bf Ir-Re Rocket, Volume 1

This report describes the AJ10-221, a high performance Iridium-coated Rhenium (Ir-Re) 110 lbf (490N) welded rocket chamber with 286:1 area ratio nozzle. This engine was designed, built, and hot fired for over 6 hours on this program. It demonstrated an I(s) of 321.8 sec, which is 10 sec higher than conventional 110 lbf silicide coated Cb chambers now in use. The approach used in this portion of the program was to demonstrate the performance improvement that can be made by the elimination of fuel film cooling and the use of a high temperature (4000F) (2200C) iridium-coated rhenium (Ir-Re) rocket chamber. Detailed thermal, performance, mechanical, and dynamic design analyses of the full engine were conducted by Aerojet. Two Ir-Re chambers were built to the Aerojet design by Ultramet, using the chemical vapor deposition (CVD) process. Incorporation of a secondary mixing device or Boundary Layer Trip (BLT) within the combustion chamber (Aerojet Patents 4882904 and 4936091) results in improvement in flow uniformity, and a significant life and performance increase. The 110 lbf engine design was verified in bolt-up hardware tests at sea level and altitude. The effects of injector design on performance were studied. Two duplicate injectors were fabricated matching the preferred design and were demonstrated to be interchangeable in operation. One of these units was fabricated matching the preferred design and was demonstrated to be interchangeable in operation. One of these units was welded into a flight type thruster which was tested for an accumulated duration of 22,590 sec in 93 firings, one of which was a continuous burn of two hours. A design deficiency in the C-103 nozzle near the Re-Cb transition joint was discovered, studied and corrected design has been prepared. Workhardening studies have been conducted to investigate methods for increasing the low yield strength of the Re in the annealed conditions. An advanced 490N high performance engine has been demonstrated which, when proven to be capable of withstanding launch vibration, is ready for flight qualification.

Jassowski, Donald M.↗
NASA NTRS2003

Operational Issues in the Development of a Cost-Effective Reusable LOX/LH2 Engine

The NASA Space Launch Initiative (SLI) was initiated in early 2001 to conduct technology development and to reduce the business and technical risk associated with developing the next-generation reusable launch system. In the field of main propulsion, two LOXLH2 rocket engine systems, the Pratt & Whitney / Aerojet Joint Venture (JV) COBRA and the Rocketdyne RS-83, were funded to develop a safe, economical, and reusable propulsion system. Given that a large-thrust reusable rocket engine program had not been started in the U.S. since 1971, with the Space Shuttle Main Engine (SSME), this provided an opportunity to build on the experience developed on the SSME system, while exploiting advances in technology that had occurred in the intervening 30 years. One facet of engine development that was identified as being especially vital in order to produce an optimal system was in the areas of operability and maintainability. In order to achieve the high levels of performance required by the Space Shuttle, the SSME system is highly complex with very tight tolerances and detailed requirements. Over the lifetime of the SSME program, the engine has required a high level of manpower to support the performance of inspections, maintenance (scheduled and unscheduled) and operations (prelaunch and post-flight). As a consequence, the labor- intensive needs of the SSME provide a significant impact to the overall cost efficiency of the Space Transportation System (STS). One of the strategic goals of the SLI is to reduce cost by requiring the engine(s) to be easier (Le. less expensive) to operate and maintain. The most effective means of accomplishing this goal is to infuse the operability and maintainability features into the engine design from the start. This paper discusses some of the operational issues relevant to a reusable LOx/LH2 main engine, and the means by which their impact is mitigated in the design phase.

Ballard, Richard O.↗