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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

CATIA V5 Virtual Environment Support for Constellation Ground Operations

This summer internship primarily involved using CATIA V5 modeling software to design and model parts to support ground operations for the Constellation program. I learned several new CATIA features, including the Imagine and Shape workbench and the Tubing Design workbench, and presented brief workbench lessons to my co-workers. Most modeling tasks involved visualizing design options for Launch Pad 39B operations, including Mobile Launcher Platform (MLP) access and internal access to the Ares I rocket. Other ground support equipment, including a hydrazine servicing cart, a mobile fuel vapor scrubber, a hypergolic propellant tank cart, and a SCAPE (Self Contained Atmospheric Protective Ensemble) suit, was created to aid in the visualization of pad operations.

Kelley, Andrew↗
NASA NTRS2014

An Overview of the Concept of Operations for Assembly, Integration, Testing and Ground Servicing Developed for the MPCV-ESM Propulsion System

A concept of operations for the Assembly, Integration and Testing (AIT) and the Ground Systems Development Operations (GSDO) of the European Service Module (ESM) propulsion system has been developed. The AIT concept of operations covers all fabrication, integration and testing activities in both Europe and in the United States. The GSDO Program develops the facilities, equipment, and procedures for the loading of hypergolic propellants, the filling of high-pressure gases, and contingency de-servicing operations for the ESM. NASA and ESA along with the Lockheed Martin and Airbus Space and Defense are currently working together for the EM-1 and EM-2 missions in which the ESM will be flown as part of the Orion Multi-Purpose Crew Vehicle (MPCV). The NASA/ESA SM propulsion team is collaborating with the AIT personnel from ESA/Airbus and NASA/Lockheed Martin to ensure successful integration of the European designed Service Module propulsion system, the Lockheed Martin designed Crew Module Adapter and the heritage Space Shuttle Orbital Maneuvering System Engines (OMS-E) being provided as Government Furnished Equipment (GFE). This paper will provide an overview of the current AIT and GSDO concept of operations for the ESM propulsion system.

Propulsion↗
NASA NTRS2014

A Historical Analysis of Crane Mishaps at Kennedy Space Center

Cranes and hoists are widely used in many areas. Crane accidents and handling mishaps are responsible for injuries, costly equipment damage, and program delays. Most crane accidents are caused by preventable factors. Understanding these factors is critical when designing cranes and preparing lift plans. Analysis of previous accidents provides insight into current recommendations for crane safety. Cranes and hoists are used throughout Kennedy Space Center to lift everything from machine components to critical flight hardware. Unless they are trained crane operators, most NASA employees and contractors do not need to undergo specialized crane training and may not understand the safety issues surrounding the use of cranes and hoists. A single accident with a crane or hoist can injure or kill people, cause severe equipment damage, and delay or terminate a program. Handling mishaps can also have a significant impact on the program. Simple mistakes like bouncing or jarring a load, or moving the crane down when it should go up, can damage fragile flight hardware and cause major delays in processing. Hazardous commodities (high pressure gas, hypergolic propellants, and solid rocket motors) can cause life safety concerns for the workers performing the lifting operations. Most crane accidents are preventable with the correct training and understanding of potential hazards. Designing the crane with human factors taken into account can prevent many accidents. Engineers are also responsible for preparing lift plans where understanding the safety issues can prevent or mitigate potential accidents. Cranes are widely used across many areas of KSC. Failure of these cranes often leads to injury, high damage costs, and significant delays in program objectives. Following a basic set of principles and procedures during design, fabrication, testing, regular use, and maintenance can significantly minimize many of these failures. As the accident analysis shows, load drops are often caused or influenced by human factors. Therefore, proper training and understanding of crane safety throughout the workforce is critical. It is important that the engineers designing the cranes, lift planners preparing the lift plans, operators performing the lifts, and training officers conducting the operator training all understand the problems that can happen with cranes and how to ensure the safety of the workforce and equipment being lifted.

Materials Handling↗
NASA NTRS2014

An Overview of the Concept of Operations for Assembly, Integration, Testing and Ground Servicing Developed for the MPCV-ESM Propulsion System

A concept of operations for the Assembly, Integration and Testing (AIT) and the Ground Systems Development Operations (GSDO) of the European Service Module (ESM) propulsion system has been developed. The AIT concept of operations covers all fabrication, integration and testing activities in both Europe and in the United States. The GSDO Program develops the facilities, equipment, and procedures for the loading of hypergolic propellants, the filling of high-pressure gases, and contingency de-servicing operations for the ESM. NASA and ESA along with the Lockheed Martin and Airbus Space and Defense are currently working together for the EM-1 and EM-2 missions in which the ESM will be flown as part of the Orion Multi-Purpose Crew Vehicle (MPCV). The NASA/ESA SM propulsion team is collaborating with the AIT personnel from ESA/Airbus and NASA/Lockheed Martin to ensure successful integration of the European designed Service Module propulsion system, the Lockheed Martin designed Crew Module Adapter and the heritage Space Shuttle Orbital Maneuvering System Engines (OMS-E) being provided as Government Furnished Equipment (GFE). This paper will provide an overview of the current AIT and GSDO concept of operations for the ESM propulsion system.

Ground Servicing↗
NASA NTRS2015

Resource Prospector Propulsion System Cold Flow Testing

Resource Prospector (RP) is a NASA mission being led by NASA Ames Research Center with current plans to deliver a scientific payload package aboard a rover to the lunar surface. As part of an early risk reduction activity, Marshall Space Flight Center (MSFC) and Johnson Space Flight Center (JSC) have jointly developed a government-version concept of a lunar lander for the mission. The spacecraft consists of two parts, the lander and the rover which carries the scientific instruments. The lander holds the rover during launch, cruise, and landing on the surface. Following terminal descent and landing the lander portion of the spacecraft become dormant after the rover embarks on the science mission. The lander will be equipped with a propulsion system for lunar descent and landing, as well as trajectory correction and attitude control maneuvers during transit to the moon. Hypergolic propellants monomethyl hydrazine and nitrogen tetroxide will be used to fuel sixteen 70-lbf descent thrusters and twelve 5-lbf attitude control thrusters. A total of four metal-diaphragm tanks, two per propellant, will be used along with a high-pressure composite-overwrapped pressure vessel for the helium pressurant gas. Many of the major propulsion system components are heritage missile hardware obtained by NASA from the Air Force. In parallel with the flight system design activities, a simulated propulsion system based on flight drawings was built for conducting a series of water flow tests to characterize the transient fluid flow of the propulsion system feed lines and to verify the critical operation modes such as system priming, waterhammer, and crucial mission duty cycles. The primary objective of the cold flow testing was to simulate the RP propulsion system fluid flow operation through water flow testing and to obtain data for anchoring analytical models. The models will be used to predict the transient and steady state flow behaviors in the actual flight operations. All design and build efforts, including the analytical modeling, have been performed. The cold flow testing of the propulsion system was set up and conducted at a NASA MSFC test facility. All testing was completed in the summer of 2014, and this paper documents the results of that testing and the associated fluid system modeling efforts.

Williams, Hunter↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
NASA NTRS2019

Analysis of Base Heating Environment During Ground Testing of a Lunar Lander Demonstrator

Introduction: This lunar lander demonstrator, known as XL-1T (terrestrial), is a collaborative effort between Masten Space Systems and NASA, under NASA’s Lunar CATALYST (also known as Lunar Cargo Transportation and Landing by Soft Touchdown) initiative; The lunar lander is a reusable terrestrial test bed for Masten’s powered decent landing system, and will be controlled by four throttleable main engines utilizing green hypergolic propellants; One of the concerns for a four-engine vehicle like this demonstrator, is the potential for a severe base-heating environment, caused by the formation of a “fountain jet” during testing. Fountain jet is an unique base flow physics which was discovered during the development of the DC-X vehicle.

Wang, Ten-See↗
NASA NTRS2019

A Streamlined Approach to Spatial Mapping of Complex 3D Thermal Boundary Condition Data

Spatial mapping of 1D, 2D, and particularly 3D thermal boundary condition data is essential for accurate thermal simulation of spacecraft and launch vehicles. This information typically is available in simple ASCII file format but can be problematic to use for thermal simulations. Difficulties that can be encountered include the ability to directly use the available file format, transformation of the data into the desired reference coordinate system in 3D space, and accurate interpolation of the data onto the thermal calculation domain. This paper presents a streamlined approach to spatial mapping of complex unsymmetrical 3D cold wall heat flux data using the fields’ capability in Simcenter3D. A recent example of 3D thermal plume simulation at MSFC will be employed to illustrate the use of text, csv, and Excel files, specifying coordinate systems for transformation of data in 3D space, and use of the various interpolation schemes available for spatial mapping. Spatial boundary condition verification is also very important, and the spacecraft thermal analyst needs effective visualization tools to develop confidence in the boundary condition definitions. Visualization of the spacecraft plume raw field data, the calculated field data, and the interpolated field data onto the thermal calculation domain will be discussed, with a particular focus on real-time viewing of the interpolated data for available interpolation schemes. The objective of this paper is to outline the modeling techniques used with the integrated thermal analysis of a terrestrial lunar lander demonstrator. Specifically, the techniques outlined herein focus on spatial mapping of convective and radiative exhaust plume results from a computational fluid dynamics (CFD) analysis. Two cases were investigated, however, the modeling techniques that were utilized translate to both cases seamlessly. Those two cases were as follows: • Lunar lander demonstrator firing on-pad (worst case). • Lunar lander demonstrator hovering at an elevated position above the launch pad. For the purposes of information control, this paper will focus on the modeling techniques only, using altered or dimensionless data where necessary. BACKGROUND The thermal model examined in this paper is of the lunar lander demonstrator known as XL-1T (terrestrial), born from a collaborative effort between Masten Space Systems (MSS) and NASA, under NASA’s Lunar CATALYST (also known as Lunar Cargo Transportation and Landing by Soft Touchdown) initiative. The lander is a reusable vertical takeoff/vertical landing (VTVL) test bed which is controlled by four throttleable main engines utilizing green hypergolic propellants.

Hawkins, Robert F.↗
NASA NTRS2020

Mars Ascent Vehicle Hybrid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. The initial MSR architecture called for a hybrid-based propulsion MAV. This type of propulsion system calls for a solid wax motor that would utilize liquid MON-25 as an oxidizer. Hybrid rocket propulsion allows for more flexibility than traditional solid or liquid propulsion options, and typically benefits from the advantages of both. A hybrid motor can be throttled and shut down easily, and avoids significant risk in manufacturing and handling. On a theoretical level, hybrid motors perform at a higher specific impulse (Isp) than solid motors. The primary disadvantage of hybrid motors comes from additional complexity and significantly less flight heritage and low Technology Readiness Level (TRL). This paper describes the design of the hybrid propulsion configuration. An additional paper will be published describing the design of the solid propulsion configuration1. The hybrid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features a Single Stage to Orbit (SSTO) design with an SP7A solid wax fuel and MON-25 liquid oxidizer. The liquid portion of the vehicle allows for a Liquid Injection Thrust Vector Controller (LITVC) as well as hypergolic propellant additives for ignition. The vehicle was designed to deliver approximately 0.31kg of Martian geological samples to a circular orbit at Mars of 343km at a 25o inclination. Although hybrid propulsion in general has been used on launch vehicles in the past, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40oC. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), LITVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗
NASA NTRS2024

Lessons Learned from Particulate Characterization Laboratory Anomalies

The White Sands Test Facility chemistry laboratory provides quality control for cleanroom operations including cleanliness verification of aerospace hardware by particulate counts and non-volatile residue determinations, particulate counts for liquid hypergolic propellants, gaseous helium and nitrogen propellant pressurizing agents used for ground support equipment and flight test article valve actuation, gaseous oxygen primarily used for component testing, and deionized water for refurbished propellant hardware flushing. Cleanliness verification includes particulate counts and non-volatile residue determinations to industry standard, NASA, and program specifications and levels. Particulate counts are typically to customer-specified specifications and levels including JPR 5322.1H (2016) Levels 50 and 100, Orion (MPCV 70156. Revision H (2018)) Level 100, RPTSTD-8070-0001 Revision 3 (2022), and IEST-STD-CC1246E (2013) Levels 50 and 100. The laboratory issues high pressure filter holders containing membrane filters to test operations personnel, who collect samples by flowing the required volumes of fluid through the filter holder, and the filter holder is returned to the lab for counting. A passing particulate count is required before testing may proceed. Rapid data reduction and issuing of reports indicating a pass or fail of the particulate specification are required. Corrective action and resampling invariably occurs if a sample fails. Consequently, the laboratory must maintain the highest degree of reliability to facilitate quality data used to decide if testing may proceed. Experience and continual improvements have enabled reliability. However, anomalies attributed to lab processes and hardware including filter holders, membranes, and Petri dishes have been encountered. This paper presents a summary of problems, solutions, successes, and lessons learned from particle counting experience for over 35 years.

Lessons Learned↗
NASA NTRS2026

On-Demand Production of Hypergols: Steps Towards Scalability

During FY 2025, the team at KSC focused on taking the 2024 proof-of-concept demonstration of hypergol production using novel methods and began scaling up production and increasing purity. The team was able to more than triple the production of hydrazine using a novel method with a drastic increase in the purity. The current method, albeit still limited to production rates on the order of mg/hr, provides a cost savings of approximately 14x when compared to market value pricing through the Defense Logistics Agency (DLA) website. The benefit of this technology is the ability to produce some hypergolic fuels using constituents in Earth’s atmosphere, eliminating most chemical commodity logistics. This technology also allows for the return of domestic production of hypergolic propellant.

Kenneth Engeling↗
NASA NTRS1974

The hard start phenomena in hypergolic engines. Volume 2: Combustion characteristics of propellants and propellant combinations

The combustion characteristics of hypergolic propellants are described. A research project was conducted to determine if the reaction control system engine propellants on Apollo spacecraft undergo explosive reaction when subjected to conditions present in the engine at the time of ignition. Combustion characteristics pertinent to the hard-start phenomenon are considered. The thermal stability of frozen mixtures of hydrazine-based fuels with nitrogen tetroxide was analyzed. Results of the tests are presented in the form of tables and graphs.

Miron, Y.↗
NASA NTRS2020

NASA Engineering and Safety Center Technical Bulletin No. 20-08: Assessment of Ketazine Derived High Purity Hydrazine for Spacecraft Propellant Systems

Hydrazine and its derivatives have dominated the class of hypergolic liquid propellants for bipropellant propulsion systems in rockets such as the Titan, MX Missile, and Ariane; it has also been widely utilized as a monopropellant in auxiliary power units and in thrusters for altitude and in-orbit control of satellites and spacecraft. With continued use of hydrazine in current and future spacecraft and payloads, it is necessary to understand the historical and current states of synthesis for the commodity and possible implications that may arise from changes in production processes for the United States stock.

Ketazine↗
NASA NTRS2001

Development of an advanced rocket propellant handler's suit

Most launch vehicles and satellites in the US inventory rely upon the use of hypergolic rocket propellants, many of which are toxic to humans. These fuels and oxidizers, such as hydrazine and nitrogen tetroxide have threshold limit values as low as 0.01 PPM. It is essential to provide space workers handling these agents whole body protection as they are universally hazardous not only to the respiratory system, but the skin as well. This paper describes a new method for powering a whole body protective garment to assure the safety of ground servicing crews. A new technology has been developed through the small business innovative research program at the Kennedy Space Center. Currently, liquid air is used in the environmental control unit (ECU) that powers the propellant handlers suit (PHE). However, liquid air exhibits problems with attitude dependence, oxygen enrichment, and difficulty with reliable quantity measurement. The new technology employs the storage of the supply air as a supercritical gas. This method of air storage overcomes all of three problems above while maintaining high density storage at relatively low vessel pressures (<7000 kPa or approximately 1000 psi). A one hour prototype ECU was developed and tested to prove the feasibility of this concept. This was upgraded by the design of a larger supercritical dewar capable of holding 7 Kg of air, a supply which provides a 2 hour duration to the PHE. A third version is being developed to test the feasibility of replacing existing air cooling methodology with a liquid cooled garment for relief of heat stress in this warm Florida environment. Testing of the first one hour prototype yielded data comparable to the liquid air powered predecessor, but enjoyed advantages of attitude independence and oxygen level stability. Thermal data revealed heat stress relief at least as good as liquid air supplied units. The application of supercritical air technology to this whole body protective ensemble marked an advancement in the state-of-the-art in personal protective equipment. Not only was long duration environmental control provided, but it was done without a high pressure vessel. The unit met human performance needs for attitude independence, oxygen stability and relief of heat stress. This supercritical air (and oxygen) technology is suggested for microgravity applications in life support such as the Extravehicular Mobility Unit. c 2001. Elsevier Science Ltd. All rights reserved.

Hazardous Substances↗