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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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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions

A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.

Morehead, Robert L.↗
NASA NTRS1987

Space Shuttle Main Engine plume spectral monitoring preliminary results

In order to provide the information necessary to develop a rocket engine ground test failure detection monitor which keys on anomalous activity in the plume, a series of experimental observations were made during single engine Space Shuttle Main Engine (SSME) tests. The observations were conducted from the 220 nm wavelength in the ultraviolet out to the 15 micron wavelength in the infrared. Four types of instruments were employed including analog autoranging narrow band radiometers, optical multichannel analyzers, mechanical scanning and film plate spectrometers, and imaging cameras. Some results included: strong OH radiation in the UV up to vibrational transition state four; Na and K radiation lines in all phases of engine operation; reaction of some of the instruments to minor engine anomalies; good shock structure imaging; striations in the flow in the 310 nm OH band; and detection of gross changes in engine operating state such as start or shutdown.

Cikanek, H. A., III↗
NASA NTRS2011

Advanced Development of a Compact 5-15 lbf Lox/Methane Thruster for an Integrated Reaction Control and Main Engine Propulsion System

This paper describes the advanced development and testing of a compact 5 to 15 lbf LOX/LCH4 thruster for a pressure-fed integrated main engine and RCS propulsion system to be used on a spacecraft "vertical" test bed (VTB). The ability of the RCS thruster and the main engine to operate off the same propellant supply in zero-g reduces mass and improves mission flexibility. This compact RCS engine incorporates several features to dramatically reduce mass and parts count, to ease manufacturing, and to maintain acceptable performance given that specific impulse (Isp) is not the driver. For example, radial injection holes placed on the chamber body for easier drilling, and high temperature Haynes 230 were selected for the chamber over other more expensive options. The valve inlets are rotatable before welding allowing different orientations for vehicle integration. In addition, the engine design effort selected a coil-on-plug ignition system which integrates a relay and coil with the plug electrode, and moves some exciter electronics to avionics driver board. The engine injector design has small dribble volumes to target minimum pulse widths of 20 msec. and an efficient minimum impulse bit of less than 0.05 lbf-sec. The propellants, oxygen and methane, were chosen because together they are a non-toxic, Mars-forward, high density, space storable, and high performance propellant combination that is capable of pressure-fed and pump-fed configurations and integration with life support and power subsystems. This paper will present the results of the advanced development testing to date of the RCS thruster and the integration with a vehicle propulsion system.

Hurlbert, Eric A.↗
NASA NTRS1992

Determination of YAV-8B Reaction Control System bleed flow usage

Using a calibrated Rolls-Royce Pegasus engine, total Reaction Control System (RCS) bleed flow rates have been measured on a YAV-8B Harrier during typical short takeoff, transition, hover and vertical landing maneuvers. Using existing aircraft instrumentation and pressure taps located in the RCS ducts, bleed flow rates at each RCS valve were also measured directly during flight and ground tests. These data were compared with the calibrated engine data and with the RCS part of a YAV-8B mathematical model used in piloted simulation at NASA Ames Research Center. Areas of disagreement were small, being confined to the estimation of closed RCS valve leakages and the modeling of the RCS butterfly valve pressure losses.

Borchers, Paul F.↗
NASA NTRS1974

The hard start phenomena in hypergolic engines. Volume 3: Physical and combustion characteristics of engine residuals

An investigation was conducted to determine the cause of starting problems in the hypergolic rocket engines of the Apollo reaction control (RCS) engines. The scope of the investigation was as follows: (1) to establish that chemical reactions occurred during the preignition and post combustion periods, (2) to identify the chemical species of the products of preignition and post combustion reaction, and (3) to determine the explosive nature of the identified species. The methods used in identifying the chemical products are described species. The infrared spectra, X-ray spectra, and other signatures of the compounds are presented. The physical and explosion characteristics of various hypergolic agents are reported.

Miron, Y.↗
NASA NTRS2013

High-Pressure Lightweight Thrusters

Returning samples of Martian soil and rock to Earth is of great interest to scientists. There were numerous studies to evaluate Mars Sample Return (MSR) mission architectures, technology needs, development plans, and requirements. The largest propulsion risk element of the MSR mission is the Mars Ascent Vehicle (MAV). Along with the baseline solid-propellant vehicle, liquid propellants have been considered. Similar requirements apply to other lander ascent engines and reaction control systems. The performance of current state-ofthe- art liquid propellant engines can be significantly improved by increasing both combustion temperature and pressure. Pump-fed propulsion is suggested for a single-stage bipropellant MAV. Achieving a 90-percent stage propellant fraction is thought to be possible on a 100-kg scale, including sufficient thrust for lifting off Mars. To increase the performance of storable bipropellant rocket engines, a high-pressure, lightweight combustion chamber was designed. Iridium liner electrodeposition was investigated on complex-shaped thrust chamber mandrels. Dense, uniform iridium liners were produced on chamber and cylindrical mandrels. Carbon/carbon composite (C/C) structures were braided over iridium-lined mandrels and densified by chemical vapor infiltration. Niobium deposition was evaluated for forming a metallic attachment flange on the carbon/ carbon structure. The new thrust chamber was designed to exceed state-of-the-art performance, and was manufactured with an 83-percent weight savings. High-performance C/Cs possess a unique set of properties that make them desirable materials for high-temperature structures used in rocket propulsion components, hypersonic vehicles, and aircraft brakes. In particular, more attention is focused on 3D braided C/Cs due to their mesh-work structure. Research on the properties of C/Cs has shown that the strength of composites is strongly affected by the fiber-matrix interfacial bonding, and that weakening interface realizes pseudo-plastic behavior with significant increase in the tensile strength. The investigation of high-temperature strength of C/Cs under high-rate heating (critical for thrust chambers) shows that tensile and compression strength increases from 70 MPa at room temperature to 110 MPa at 1,773 K, and up to 125 MPa at 2,473 K. Despite these unique properties, the use of C/Cs is limited by its high oxidation rate at elevated temperatures. Lining carbon/carbon chambers with a thin layer of iridium or iridium and rhenium is an innovative way to use proven refractory metals and provide the oxidation barrier necessary to enable the use of carbon/ carbon composites. Due to the lower density of C/Cs as compared to SiC/SiC composites, an iridium liner can be added to the C/C structure and still be below the overall thruster weight. Weight calculations show that C/C, C/C with 50 microns of Ir, and C/C with 100 microns of Ir are of less weight than alternative materials for the same construction.

Holmes, Richard↗
NASA NTRS2008

Liquid Methane/Liquid Oxygen Propellant Conditioning Feed System (PCFS) Test Rigs

As part of their Propulsion and Cryogenic Advanced Development (PCAD) program, NASA has embarked upon an effort to develop chemical rocket engines which utilize non-toxic, cryogenic propellants such as liquid oxygen (LO2) and liquid methane (LCH4). This effort includes the development and testing of a 100 lbf Reaction Control Engine (RCE) that will be used to evaluate the performance of a LO2/LCH4 rocket engine over a broad range of propellant temperatures and pressures. This testing will take place at NASA-Glenn Research Center's (GRC) Research Combustion Laboratory (RCL) test facility in Cleveland, OH, and is currently scheduled to begin in late 2008. While the initial tests will be performed at sea level, follow-on testing will be performed at NASA-GRC's Altitude Combustion Stand (ACS) for altitude testing. In support of these tests, Sierra Lobo, Inc. (SLI) has designed, developed, and fabricated two separate portable propellant feed systems under the Propellant Conditioning and Feed System (PCFS) task: one system for LCH4, and one for LO2. These systems will be capable of supplying propellants over a large range of conditions from highly densified to several hundred pounds per square inch (psi) saturated. This paper presents the details of the PCFS design and explores the full capability of these propellant feed systems.

Skaff, A.↗
NASA NTRS2018

Generic Control Allocation Toolbox for Preliminary Vehicle Design

This paper describes the development and application of a Generic Control Allocation Toolbox developed at NASA Langley Research Center (LGCAT) intended to aid engineers during the preliminary design phase of an aerospace vehicle. The static controllability space in the forms of a Theoretical Attainable Moment Set, Φ, or Theoretical Attainable Force Set, φ is difficult to visualize for modern vehicles with multiple types of redundant control effectors. The objective of LGCAT is to provide system engineers and designers early in the vehicle design phase with quick insights on how control effector parameters such as quantity, sizing, location, orientation, redundancy, etc., affect the overall controllability and other performance metrics. Having such information in hand allows system engineers to make more informed decisions on overall mission objectives such as performance vs. reliability vs. cost, etc. early in a vehicle design phase and reduce the number of iterations necessary in the design and analysis cycles. LGCAT can accept a variety of control effector types including aerodynamic surfaces, rotors, thrust vector control (TVC) engines, and reaction control systems (RCS). LGCAT is MATLAB based, user friendly, and is capable of performing the analysis in the Graphical User Interface (GUI) or script mode. Current add-on features include interfacing with engineering level codes such as Vehicle Sketch Pad (VSP) and generating the corresponding Φ and φ for an arbitrary vehicle design. These capabilities potentially make LGCAT an integral part of the preliminary design phase for any vehicle.

Pei, Jing↗
NASA NTRS2015

Improved Rhenium Thrust Chambers

Radiation-cooled bipropellant thrust chambers are being considered for ascent/ descent engines and reaction control systems on various NASA missions and spacecraft, such as the Mars Sample Return and Orion Multi-Purpose Crew Vehicle (MPCV). Currently, iridium (Ir)-lined rhenium (Re) combustion chambers are the state of the art for in-space engines. NASA's Advanced Materials Bipropellant Rocket (AMBR) engine, a 150-lbf Ir-Re chamber produced by Plasma Processes and Aerojet Rocketdyne, recently set a hydrazine specific impulse record of 333.5 seconds. To withstand the high loads during terrestrial launch, Re chambers with improved mechanical properties are needed. Recent electrochemical forming (EL-Form"TM") results have shown considerable promise for improving Re's mechanical properties by producing a multilayered deposit composed of a tailored microstructure (i.e., Engineered Re). The Engineered Re processing techniques were optimized, and detailed characterization and mechanical properties tests were performed. The most promising techniques were selected and used to produce an Engineered Re AMBR-sized combustion chamber for testing at Aerojet Rocketdyne.

O'Dell, John Scott↗
NASA NTRS1993

Fail-Safe Pressure Plug

Protective plug resists slowly built-up pressure or automatically releases itself if pressure rises suddenly. Seals out moisture at pressures ranging from 50 micrometers of mercury to 200 pounds per square inch. Designed to seal throat of 38 Reaction Control Thrusters on Space Shuttle protecting internal components from corrosion. Plug conforms to contour of nozzle throat, where O-ring forms pressure seal. After plug inserted, cover attached by use of cover-fitting assembly. Modified versions useful in protecting engines, pumps, reaction vessels, and other industrial equipment during shipment and maintenance.

Svejkovsky, Paul A.↗
NASA NTRS1972

Space Shuttle bipropellant RCS engine.

The requirements of the Space Shuttle bipropellant reaction control system engine technology contract and the scheduled contract effort are presented herein. The requirements included an engine concept scalable from 400 to 1100 lbf, with a 100 mission life employing N2O4/MMH propellants. Emphasis is placed on reusability and minimum post-flight servicing. The engine components are reviewed and their selection is supported by tradeoff analyses, thrust chamber firing test data, materials test data, and metallurgical evaluations. The materials test data indicate that the proposed silicide coated columbium chamber and uncoated columbium injector have the potential of meeting the mission life requirements. The engine valve trade studies resulted in the selection of a torque motor operated bipropellant valve configuration. Fuel vortex film cooling of the insulated chamber is described together with the fuel vortex film cooling scaling parameter and its verification by test data to a thrust level of 5500 lbf.

Sanscrainte, W.↗
NASA NTRS1983

Shuttle measured contaminant environment and modeling for payloads. Preliminary assessment of the space telescope environment in the shuttle bay

A baseline gaseous and particulate environment of the Shuttle bay was developed based on the various measurements which were made during the first four flights of the Shuttle. The environment is described by the time dependent pressure, density, scattered molecular fluxes, the column densities and including the transient effects of water dumps, engine firings and opening and closing of the bay doors. The particulate conditions in the ambient and on surfaces were predicted as a function of the mission time based on the available data. This basic Shuttle environment when combined with the outgassing and the particulate contributions of the payloads, can provide a description of the environment of a payload in the Shuttle bay. As an example of this application, the environment of the Space Telescope in the bay, which may be representative of the environment of several payloads, was derived. Among the many findings obtained in the process of modeling the environment, one is that the payloads environment in the bay is not substantially different or more objectionable than the self-generated environment of a large payload or spacecraft. It is, however, more severe during ground facilities operations, the first 15 to 20 hours of the flight, during and for a short period after ater was dumped overboard, and the reaction control engines are being fired.

Scialdone, J. J.↗