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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 NTRS2010

TRL Assessment of Solar Sail Technology Development Following the 20-Meter System Ground Demonstrator Hardware Testing

The NASA In-Space Propulsion Technology (ISPT) Projects Office sponsored two separate, independent solar sail system design and development demonstration activities during 2002-2005. ATK Space Systems of Goleta, CA was the prime contractor for one development team and L' Garde, Inc. of Tustin, CA was the prime contractor for the other development team. The goal of these activities was to advance the technology readiness level (TRL) of solar sail propulsion from 3 towards 6 by the year 2006. Component and subsystem fabrication and testing were completed successfully, including the ground deployment of 10-meter and 20-meter demonstration hardware systems under vacuum conditions. The deployment and structural testing of the 20-meter solar sail systems was conducted in the 30 meter diameter Space Power Facility thermal-vacuum chamber at NASA Glenn Plum Brook in April though August, 2005. This paper will present the results of the TRL assessment following the solar sail technology development activities associated with the design, development, analysis and testing of the 20-meter system ground demonstrators.

Young, Roy M.↗

NASA NTRS2001

Deep Space 1 Ion Engine Completed a 3-Year Journey

A xenon ion engine and power processor system, which was developed by the NASA Glenn Research Center in partnership with the Jet Propulsion Laboratory and Boeing Electron Dynamic Devices, completed nearly 3 years of operation aboard the Deep Space 1 spacecraft. The 2.3-kW ion engine, which provided primary propulsion and two-axis attitude control, thrusted for more than 16,000 hr and consumed more than 70 kg of xenon propellant. The Deep Space 1 spacecraft was launched on October 24, 1998, to validate 12 futuristic technologies, including the ion-propulsion system. After the technology validation process was successfully completed, the Deep Space 1 spacecraft flew by the small asteroid Braille on July 29, 1999. The final objective of this mission was to encounter the active comet Borrelly, which is about 6 miles long. The ion engine was on a thrusting schedule to navigate the Deep Space 1 spacecraft to within 1400 miles of the comet. Since the hydrazine used for spacecraft attitude control was in short supply, the ion engine also provided two-axis attitude control to conserve the hydrazine supply for the Borrelly encounter. The comet encounter took place on September 22, 2001. Dr. Marc Rayman, project manager of Deep Space 1 at the Jet Propulsion Laboratory said, "Deep Space 1 plunged into the heart of the comet Borrelly and has lived to tell every detail of its spinetingling adventure! The images are even better than the impressive images of comet Halley taken by Europe's Giotto spacecraft in 1986." The Deep Space 1 mission, which successfully tested the 12 high-risk, advanced technologies and captured the best images ever taken of a comet, was voluntarily terminated on December 18, 2001. The successful demonstration of the 2-kW-class ion propulsion system technology is now providing mission planners with off-the-shelf flight hardware. Higher power, next generation ion propulsion systems are being developed for large flagship missions, such as outer planet explorers and sample-return missions.

Sovey, James S.↗

NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the manned maneuvering unit

Results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items (PCIs). To preserve indepedence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results corresponding to the Manned Maneuvering Unit (MMU) hardware. The MMU is a propulsive backpack, operated through separate hand controllers that input the pilot's translational and rotational maneuvering commands to the control electronics and then to the thrusters. The IOA analysis process utilized available MMU hardware drawings and schematics for defining hardware subsystems, assemblies, components, and hardware items. Final levels of detail were evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the worst case severity of the effect for each identified failure mode. The IOA analysis of the MMU found that the majority of the PCIs identified are resultant from the loss of either the propulsion or control functions, or are resultant from inability to perform an immediate or future mission. The five most severe criticalities identified are all resultant from failures imposed on the MMU hand controllers which have no redundancy within the MMU.

Bailey, P. S.↗

NASA NTRS2009

A Summary of NASA and USAF Hypergolic Propellant Related Spills and Fires

Several unintentional hypergolic fluid related spills, fires, and explosions from the Apollo Program, the Space Shuttle Program, the Titan Program, and a few others have occurred over the past several decades. Spill sites include the following government facilities: Kennedy Space Center (KSC), Johnson Space Center (JSC), White Sands Test Facility (WSTF), Vandenberg Air Force Base (VAFB), Cape Canaveral Air Force Station (CCAFS), Edwards Air Force Base (EAFB), Little Rock AFB, and McConnell AFB. Until now, the only method of capturing the lessons learned from these incidents has been "word of mouth" or by studying each individual incident report. The root causes and consequences of the incidents vary drastically; however, certain "themes" can be deduced and utilized for future hypergolic propellant handling. Some of those common "themes" are summarized below: (1) Improper configuration control and internal or external human performance shaping factors can lead to being falsely comfortable with a system (2) Communication breakdown can escalate an incident to a level where injuries occur and/or hardware is damaged (3) Improper propulsion system and ground support system designs can destine a system for failure (4) Improper training of technicians, engineers, and safety personnel can put lives in danger (5) Improper PPE, spill protection, and staging of fire extinguishing equipment can result in unnecessary injuries or hardware damage if an incident occurs (6) Improper procedural oversight, development, and adherence to the procedure can be detrimental and quickly lead to an undesirable incident (7) Improper materials cleanliness or compatibility and chemical reactivity can result in fires or explosions (8) Improper established "back-out" and/or emergency safing procedures can escalate an event The items listed above are only a short list of the issues that should be recognized prior to handling hypergolic fluids or processing vehicles containing hypergolic propellants. The summary of incidents in this report is intended to cover many more issues than those listed above.

Nufer, Brian M.↗

NASA NTRS2009

Lessons Learned Entry: Hypergolic Propellant Related Spills and Fires

The attached report is a compilation of all credible, unintentional hypergolic fluid related spills, fires, and explosions from the Apollo Program, the Space Shuttle Program, Titan Program, and a few other programs. Spill sites include the following government facilities: KSC, JSC, WSTF, VAFB, CCAFS, EAFB, Little Rock AFB, and McConnell AFB. The root causes and consequences of the incidents contained in this document vary drastically; however, certain "themes" can be deduced and utilized for future hypergolic propellant handling. Some of those common "themes" are summarized below: (1) Improper configuration control and complacency can lead to being falsely comfortable with a system (2) Communication breakdown can escalate an incident to a level where injuries occur and/or hardware is damaged (3) Improper propulsion system and ground support system designs can destine a system for failure (4) Improper training of technicians, engineers, and safety personnel can put lives in danger (5) Improper PPE, spill protection, and staging of fire extinguishing equipment can result in unnecessary injuries or hardware damage if an incident occurs (6) Improper procedural oversight, development, and adherence to the procedure can be detrimental and quickly lead to an undesirable incident (7) Improper local cleanliness or compatibility can result in fires or explosions The items listed above are only a short list of the issues that should be recognized prior to handling of hypergolic fluids or processing of vehicles containing hypergolic propellants. The summary of incidents in this report is intended to cover many more issues than those listed above that have been found during nearly the entire spectrum. of hypergolic propellant and/or vehicle processing.

Nufer, Brian↗

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 NTRS1989

The JPL telerobot operator control station. Part 1: Hardware

The Operator Control Station of the Jet Propulsion Laboratory (JPL)/NASA Telerobot Demonstrator System provides the man-machine interface between the operator and the system. It provides all the hardware and software for accepting human input for the direct and indirect (supervised) manipulation of the robot arms and tools for task execution. Hardware and software are also provided for the display and feedback of information and control data for the operator's consumption and interaction with the task being executed. The hardware design, system architecture, and its integration and interface with the rest of the Telerobot Demonstrator System are discussed.

Kan, Edwin P.↗

NASA NTRS2006

A Fast Technology Infusion Model for Aerospace Organizations

A multi-year Fast Technology Infusion initiative proposes a model for aerospace organizations to improve the cost-effectiveness by which they mature new, in-house developed software and hardware technologies for space mission use. The first year task under the umbrella of this initiative will provide the framework to demonstrate and document the fast infusion process. The viability of this approach will be demonstrated on two technologies developed in prior years with internal Jet Propulsion Laboratory (JPL) funding. One hardware technology and one software technology were selected for maturation within one calendar year or less. The overall objective is to achieve cost and time savings in the qualification of technologies. At the end of the recommended three-year effort, we will have demonstrated for six or more in-house developed technologies a clear path to insertion using a documented process that permits adaptation to a broad range of hardware and software projects.

technology readiness level↗

NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in the past year, including firing tests of both main propulsion elements, manufacturing of flight hardware, and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons (t) (154,000 pounds) of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 t (286,000 pounds) to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware, including flight hardware for Exploration Mission 1 (EM-1). This paper will provide an overview of the progress made over the past year and provide a glimpse of upcoming milestones on the way to a 2018 launch readiness date.

May, Todd↗

NASA NTRS1985

Heavy Lift Launch Vehicles for 1995 and Beyond

A Heavy Lift Launch Vehicle (HLLV) designed to deliver 300,000 lb to a 540 n mi circular polar orbit may be required to meet national needs for 1995 and beyond. The vehicle described herein can accommodate payload envelopes up to 50 ft diameter by 200 ft in length. Design requirements include reusability for the more expensive components such as avionics and propulsion systems, rapid launch turnaround time, minimum hardware inventory, stage and component flexibility and commonality, and low operational costs. All ascent propulsion systems utilize liquid propellants, and overall launch vehicle stack height is minimized while maintaining a reasonable vehicle diameter. The ascent propulsion systems are based on the development of a new liquid oxygen/hydrocarbon booster engine and liquid oxygen/liquid hydrogen upper stage engine derived from today's SSME technology. Wherever possible, propulsion and avionics systems are contained in reusable propulsion/avionics modules that are recovered after each launch.

Toelle, R.↗

NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

I. Motivation and Background Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall Current Thruster in support of the NASA mission to establish a permanent human presence in lunar orbit and to land the next American astronauts on the South Pole of the Moon. The project is led by the NASA Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by L3 Harris Aerojet Rocketdyne (AR).The AEPS project has completed the development testing of a high power, solar electric propulsion Hall Current thruster that will be used on the NASA Power & Propulsion Element (PPE) of the Gateway space station. NASA initially built three Technology Development Units to understand key characteristics of the hall-effect rocket with magnetic shielding. The design led to development testing on two Engineering Test Unit Thrusters and multiple critical components. The project has begun production of the three flight thrusters and entered qualification testing at the component and thruster levels. II. Approach NASA and AR teams completed all development phases of the project, including full development and integration testing of the Engineering Model hardware, Critical Design Review, and ground test equipment validation, as well as fabrication and acceptance testing of the initial qualification thruster. Qualification and verification of the environmental and life requirements of the AEPS design was initiated in the Fall of 2023 and will be accomplished on two thruster units and using a series of component-level tests during 2024 and 2025. Environmental testing will incorporate functional reference firings, shock, vibration, and Thermal Vacuum (TVAC) testing. Life verification will assess the thruster wear and performance over the lifetime of the Gateway spacecraft. Critical component qualification tests include cathode heater, magnet coils, magnet heaters, temperature sensors, and a cathode assembly that will undergo life cycle testing on multiple units. Flight thrusters will complete assembly and acceptance testing and be delivered to the PPE program in early 2025. III. Preliminary and Anticipated Results The program has completed the acceptance testing, including dynamic testing and hot fire characterization, of the first qualification thruster. In the Fall of 2023, the program entered the environmental qualification phase for thruster testing. This paper will present an overview of the AEPS thruster project, thruster capabilities and flight design, preliminary results from the thruster acceptance and qualification testing, component life cycle testing and flight hardware status.

Clayton Kachele↗

NASA NTRS2002

Test Facilities in Support of High Power Electric Propulsion Systems

Successful development of space fission systems requires an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system performance and lifetime can be attained through non-nuclear testing. Through demonstration of systems concepts (designed by DOE National Laboratories) in relevant environments, this philosophy has been demonstrated through hardware testing in the High Power Propulsion Thermal Simulator (HPPTS). The HPPTS is designed to enable very realistic non-nuclear testing of space fission systems. Ongoing research at the HPPTS is geared towards facilitating research, development, system integration, and system utilization via cooperative efforts with DOE labs, industry, universities, and other NASA centers. Through hardware based design and testing, the HPPTS investigates High Power Electric Propulsion (HPEP) component, subsystem, and integrated system design and performance.

VanDyke, Melissa↗

NASA NTRS2005

X-37 Storable Propulsion System Design and Operations

In a response to NASA's X-37 TA-10 Cycle-1 contract, Boeing assessed nitrogen tetroxide (N2O4) and monomethyl hydrazine (MMH) Storable Propellant Propulsion Systems to select a low risk X-37 propulsion development approach. Space Shuttle lessons learned, planetary spacecraft, and Boeing Satellite HS-601 systems were reviewed to arrive at a low risk and reliable storable propulsion system. This paper describes the requirements, trade studies, design solutions, flight and ground operational issues which drove X-37 toward the selection of a storable propulsion system. The design of storable propulsion systems offers the leveraging of hardware experience that can accelerate progress toward critical design. It also involves the experience gained from launching systems using MMH and N2O4 propellants. Leveraging of previously flight-qualified hardware may offer economic benefits and may reduce risk in cost and schedule. This paper summarizes recommendations based on experience gained from Space Shuttle and similar propulsion systems utilizing MMH and N2O4 propellants. System design insights gained from flying storable propulsion are presented and addressed in the context of the design approach of the X-37 propulsion system.

Rodriguez, Henry↗

NASA NTRS2006

X-37 Storable Propulsion System Design and Operations

Rodriguez, Henry↗

NASA NTRS2004

Thermal Design and Flight Experience of the Mars Exploration Rover Spacecraft Computer-Controlled, Propulsion Line Heaters

The viewgraph presentation examines propulsion line heater design and problems in the Mars Rover. Topics include a Mars Exploration Rover (MER) project description and MER spacecraft configuration, mission overview, MER cruise stage hardware, thermal design drivers in the propulsion lines, propulsion line control set points prior to launch, MER A and B flight trajectories, MER A early and mid cruise flight experience, MER A and B mid cruise flight experience, MER B late cruise flight experience, and lessons learned

propulsion lines↗

NASA NTRS1997

The Use of HFC (CFC Free) Processes at the NASA Stennis Space Center

The search for ozone depleting alternative chemicals was heightened when, in 1990, the more than 65 countries that had signed the Montreal Protocol agreed to phase out completely by the year 2000. In 1992, then-president Bush advanced this date for the United States to January l, 1996. In 1991, it was realized that the planned phase out and eventual elimination of ozone depleting chemicals imposed by the Montreal Protocol and the resulting Clean Air Act (CAA) amendments would impact the cleaning and testing of aerospace hardware at the NASA Stennis Space Center. Because of this regulation, the Test & Engineering Sciences Laboratory has been working on solvent conversion studies to replace CFC-113. Aerospace hardware and test equipment used in rocket propulsion systems require extreme cleanliness levels to function and maintain their integrity. Because the cleanliness of aerospace hardware will be affected by the elimination of CFC-113; alternate cleaning technologies, including the use of fluoridated solvents have been studied as potential replacements. Several aqueous processes have been identified for cleaning moderately sized components. However, no known aqueous alternative exists for cleaning and validating T&ME and complex geometry based hardware. This paper discusses the choices and the methodologies that were used to screen potential alternatives to CFC-113.

Ross, Richard H.↗

NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗

NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

Electric Propulsion↗