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As detailed in the original statement of work, the objective of phase two of this research effort was to develop a general framework for rocket engine performance prediction that integrates physical principles, a rigorous mathematical formalism, component level test data, system level test data, and theory-observation reconciliation. Specific phase two development tasks are defined.
This paper reports the results of initial efforts to apply the System Sensitivity Analysis (SSA) optimization method to the conceptual design of a single-stage-to-orbit (SSTO) launch vehicle. SSA is an efficient, calculus-based MDO technique for generating sensitivity derivatives in a highly multidisciplinary design environment. The method has been successfully applied to conceptual aircraft design and has been proven to have advantages over traditional direct optimization methods. The method is applied to the optimization of an advanced, piloted SSTO design similar to vehicles currently being analyzed by NASA as possible replacements for the Space Shuttle. Powered by a derivative of the Russian RD-701 rocket engine, the vehicle employs a combination of hydrocarbon, hydrogen, and oxygen propellants. Three primary disciplines are included in the design - propulsion, performance, and weights & sizing. A complete, converged vehicle analysis depends on the use of three standalone conceptual analysis computer codes. Efforts to minimize vehicle dry (empty) weight are reported in this paper. The problem consists of six system-level design variables and one system-level constraint. Using SSA in a 'manual' fashion to generate gradient information, six system-level iterations were performed from each of two different starting points. The results showed a good pattern of convergence for both starting points. A discussion of the advantages and disadvantages of the method, possible areas of improvement, and future work is included.
Several currently available nonmetallic insulation materials that may be bonded onto liquid-hydrogen tanks and sealed against air penetration into the insulation have been investigated for application to rockets and spacecraft. Experimental data were obtained on the thermal conductivities of various materials in the cryogenic temperature range, as well as on the structural integrity and ablation characteristics of these materials at high temperatures occasioned by aerodynamic heating during atmospheric escape. Of the materials tested, commercial corkboard has the best overall properties for the specific requirements imposed during atmospheric flight of a high-acceleration rocket vehicle.
The influence of pressure upon the signal strength and polarization properties of UV Raman signals has been investigated experimentally up to pressures of 165 psia (11 atm). No significant influence of pressure upon the Raman scattering cross section or depolarization ratio of the N2 Raman signal was found. The Raman scattering signal varied linearly with pressure for the 300 K N2 samples examined, thus showing no enhancement of cross section with increasing pressure. However at the highest pressures associated with rocket engine combustion, there could be an increase in the Raman scattering cross section, based upon others' previous work at higher pressures than those examined in this work. The influence of pressure upon thick fused silica windows, used in the NASA Modular Combustion Test Article, was also investigated. No change in the transmission characteristics of the windows occurred as the pressure difference across the windows increased from 0 psig up to 150 psig. A calibration was performed on the UV Raman system at Vanderbilt University, which is similar to the one at the NASA-Marshall Test Stand 115. The results of this calibration are described in the form of temperature-dependent functions, f(T)'s, that account for the increase in Raman scattering cross section with an increase in temperature and also account for the reduction in collected Raman signal if wavelength integration does not occur across the entire wavelength range of the Raman signal. These functions generally vary only by approximately 10% across their respective temperature ranges, except for the case Of CO2, where there is a factor of three difference in its f(T) from 300 K to 2500 K. However this trend for CO2 is consistent with the experimental work of others, and is expected based on the low characteristic vibrational temperature Of CO2. A time-averaged temperature measurement technique has been developed, using the same equipment as for the work mentioned above, that is based upon high-spectral resolution UV Raman scattering. This technique can provide temperature measurements for flows where pressure cannot be measured.
MCNP simulations have been run to evaluate the feasibility of using a combination of fast and thermal neutrons as a nondestructive method to measure of the compaction of the perlite insulation in the liquid hydrogen and oxygen cryogenic storage tanks at John F. Kennedy Space Center (KSC). Perlite is a feldspathic volcanic rock made up of the major elements Si, AI, Na, K and 0 along with some water. When heated it expands from four to twenty times its original volume which makes it very useful for thermal insulation. The cryogenic tanks at Kennedy Space Center are spherical with outer diameters of 69-70 feet and lined with a layer of expanded perlite with thicknesses on the order of 120 cm. There is evidence that some of the perlite has compacted over time since the tanks were built 1965, affecting the thermal properties and possibly also the structural integrity of the tanks. With commercially available portable neutron generators it is possible to produce simultaneously fluxes of neutrons in two energy ranges: fast (14 Me V) and thermal (25 me V). The two energy ranges produce complementary information. Fast neutrons produce gamma rays by inelastic scattering, which is sensitive to Fe and O. Thermal neutrons produce gamma rays by prompt gamma neutron activation (PGNA) and this is sensitive to Si, Al, Na, K and H. The compaction of the perlite can be measured by the change in gamma ray signal strength which is proportional to the atomic number densities of the constituent elements. The MCNP simulations were made to determine the magnitude of this change. The tank wall was approximated by a I-dimensional slab geometry with an 11/16" outer carbon steel wall, an inner stainless wall and 120 cm thick perlite zone. Runs were made for cases with expanded perlite, compacted perlite or with various void fractions. Runs were also made to simulate the effect of adding a moderator. Tallies were made for decay-time analysis from t=0 to 10 ms; total detected gamma-rays; detected gamma-rays from thermal neutron reactions d. detected gamma-rays from non-thermal neutron reactions and total detected gamma-rays as a function of depth into the annulus volume. These indicated a number of possible independent metrics of perlite compaction. For example the count rate for perlite elements increased from 3600 to 8500 cps for an increase in perlite density from 6 lbs/lcf to 16.5 lbs/cf. Thus the MCNP simulations have confirmed the feasibility of using neutron methods to map the compaction of perlite in the walls of the cryogenic tanks.
During development of the Ares I weld processes nondestructive and destructive testing were used to identify and characterize defects that occurred. These defects were named and character noted. This catalogue of defects and characteristics was then used to develop inspection methods for Self Reacting Friction Stir Welds (SR ]FSW) and Conventional Friction Stir Welds (C ]FSW). Dye penetrant, eddy current, x ]radiography, single element ultrasonic, and phased array ultrasonic (PAUT) inspection procedures were developed to target the expected defects. Once the method procedure was developed a comparison was performed to allow for selection of the best inspection method. Tests of the effectiveness of the inspection were performed on purposely fabricated flawed specimens and electrodischarge machined notches. The initial test results prompted a revisit of the PAUT procedure and a redesign of the inspection. Subsequent testing showed that a multi ]angle PAUT inspection resulted in better detection capability. A discussion of the most effective orientations of the PAUT transducer will be presented. Also, the implementation of the inspection on production hardware will be presented. In some cases the weld tool is used as the transducer manipulator and in some cases a portable scanner is used
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The research team at KSC explored the controlled passivation and burning of Lunar soil constituents in an oxygen combustion vessel for use as an in-space resource. Technologies such as carbothermal reduction (CaRD) and molten regolith electrolysis (MRE) are being developed to remove the oxygen for use and leave constituents in an enriched state. This leaves behind reduced compounds that can react with oxygen for heat generation. The team at KSC looked to explore the feasibility of controlling such reactions in a pure oxygen environment for potential technology integrations. Our proof-of-concept demonstrations have given promise to many potential applications for the controlled burning or combustion of nano- and porous silicon for silicon based, Lunar economy applications. The team at KSC was able to control the burn rate and total energy released effectively via pre-treatment of the nano-silicon in a muffle furnace at varying temperatures at one-hour durations. We created a new capability at KSC with the supporting safety documentation and procedural writeup. Our work highlights the need for greater investigation to understand the regenerative properties of the proposed porous silicon discs, and its viability of a thermal and electrical energy source. This work has demonstrated the proof-of-concept that elemental silicon is able to be combusted with gaseous and liquid oxygen in a controlled manner. This report provides such evidence as well as theoretical calculations and assumptions made for technologies that would be useful in Lunar surface operations with in-situ resources. The concepts are based on the assumption that oxygen extraction technologies from Lunar regolith processing will result in enriched silicon that may be adapted for the presented use cases. Additionally, the energy storage concept is able to be adapted for terrestrial use and integrated into already existing infrastructure.
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The design of new high-energy density molecules as candidates for jet and rocket fuels is an important goal of modern chemical thermodynamics. The NASA Glenn Research Center is home to a database of thermodynamic data for over 2000 compounds related to this goal, in the form of least-squares fits of heat capacities, enthalpies, and entropies as functions of temperature over the range of 300 - 6000 K. The chemical equilibrium with applications (CEA) program written and maintained by researchers at NASA Glenn over the last fifty years, makes use of this database for modeling the performance of potential rocket propellants. During its long history, the NASA Glenn database has been developed based on experimental results and data published in the scientific literature such as the standard JANAF tables. The recent development of efficient computational techniques based on quantum chemical methods provides an alternative source of information for expansion of such databases. For example, it is now possible to model dissociation or combustion reactions of small molecules to high accuracy using techniques such as coupled cluster theory or density functional theory. Unfortunately, the current applicability of reliable computational models is limited to relatively small molecules containing only around a dozen (non-hydrogen) atoms. We propose to extend the applicability of coupled cluster theory- often referred to as the 'gold standard' of quantum chemical methods- to molecules containing 30-50 non-hydrogen atoms. The centerpiece of this work is the concept of local correlation, in which the description of the electron interactions- known as electron correlation effects- are reduced to only their most important localized components. Such an advance has the potential to greatly expand the current reach of computational thermochemistry and thus to have a significant impact on the theoretical study of jet and rocket propellants.
While space-related cryogenic engineering in the 1950s and 1960s was primarily concerned with liquid fueled rocket fuel supply systems, the leading edge of technology development moved in the 1970s to the supply of 1.4-70 K cooling facilities for IR and gamma-ray astronomy instruments. Attention is presently given to the development history, current status, and future prospects for superfluid He cryocooling systems, in view of prospective requirements for micro-K cooling capacities over astronomical instrument service lives of the order of 10 years. The spacecraft in question will be launched in the mid-to-late 1990s and encompass the Advanced X-ray Astronomy facility, the Gyro Test of General Relativity, the Space IR Telescope Facility, Astromag, and the Submillimeter Explorer.
The Moon has been underrated as a source of H, N, C, and other elements essential to support life and to provide fuel for rockets. There is enough of these elements in each cubic meter of typical lunar soil to provide a substantial lunch for two, if converted to edible forms. The average amount of C per square meter of the lunar surface to a depth of 2 m is some 35 percent of the average amount per square meter tied up in living organisms on Earth. The water equivalent of H in the upper 2 m of the regolith averages at least 1.3 million liters per square kilometer. Mining of H from a small fraction of the regolith would provide all the rocket fuel needed for thousands of years. These elements can be removed from the soil by heating it to high temperature. Some favor the unproven resources of Phobos, Deimos, or near-Earth asteroids instead of the Moon as a source of extraterrestrial material for use in space, or Mars over the Moon as a site for habitation, partly on the basis that the chemical elements needed for life support and propellant are readily abundant on those bodies, but not on the Moon. Well, the Moon is not as barren of H, C, and N as is commonly perceived. In fact, the elements needed for life support and for rocket fuel are plentiful there, although the ore grades are low. Furthermore, the proximity of the Moon and consequent lower cost of transportation and shorter trip and communication times favor that body as the logical site for early acquisition of resources and extraterrestrial living.
Manned rocket flight in stratosphere - propulsion, propellants, and rocket fuel
Heterogeneous fuel compositions suitable for use in hybrid rocket engines and solid-fuel ramjet engines, The compositions include mixtures of a continuous phase, which forms a solid matrix, and a dispersed phase permanently distributed therein. The dispersed phase or the matrix vaporizes (or melts) and disperses into the gas flow much more rapidly than the other, creating depressions, voids and bumps within and on the surface of the remaining bulk material that continuously roughen its surface, This effect substantially enhances heat transfer from the combusting gas flow to the fuel surface, producing a correspondingly high burning rate, The dispersed phase may include solid particles, entrained liquid droplets, or gas-phase voids having dimensions roughly similar to the displacement scale height of the gas-flow boundary layer generated during combustion.
This study presents an imaging-based deep learning tool to measure the fuel regression rate in a 2D slab burner experiment for hybrid rocket fuels. The slab burner experiment is designed to verify mechanistic models of reacting boundary layer combustion in hybrid rockets by the measurement of fuel regression rates. A DSLR camera with a high intensity flash is used to capture images throughout the burn and the images are then used to find the fuel boundary to calculate the regression rate. A U-net convolutional neural network architecture is explored to segment the fuel from the experimental images. Here, a Monte-Carlo Dropout process is used to quantify the regression rate uncertainty produced from the network. The U-net computed regression rates are compared with values from other techniques from literature and show error less than 10%. An oxidizer flux dependency study is performed and shows the U-net predictions of regression rates are accurate and independent of the oxidizer flux, when the images in the training set are not over-saturated. Training with monochrome images is explored and is not successful at predicting the fuel regression rate from images with high noise. The network is superior at filtering out noise introduced by soot, pitting, and wax deposition on the chamber glass as well as the flame when compared to traditional image processing techniques, such as threshold binary conversion and spatial filtering. U-net consistently provides low error image segmentations to allow accurate computation of the regression rate of the fuel.
Catalysts for Aerozine-50 reforming and nitrogen tetroxide decomposition for development of rocket fuel cells operating on storable propellant
A system for multiple burns from a solid fuel rocket motor may extinguish rocket fuel after the rocket has been ignited. The motor may be extinguished via rapid decompression of the combustion chamber. The fuel may then be reignited by a suitable igniter, and the process of extinguishing and reigniting may be repeated, enabling multi-burn maneuvers. A decompressive extinguishing plug nozzle may extinguish solid rocket fuel after the rocket has been ignited and/or keep a rocket in a disarmed (zero thrust) state until the rocket is to be armed. The nozzle may include a plug that mostly impedes the opening of the nozzle and an outer cowl that is movable to rapidly decompress the combustion chamber. This rapid decompression extinguishes the solid rocket fuel. In some aspects, the fuel can be reignited and extinguished multiple times.
Use of high-performance aircraft as first-stage booster for air-launching solid fuel rocket - operational aspects