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NASA NTRSDate not supplied

Fundamental Regolith Properties, Handling and Water Capture (FLEET) Project Update

The FLEET project, begun in FY21, was designed to research several concepts for components and subsystems needed for extracting water from planetary ice deposits. This is one of two approaches for providing water off-Earth for direct use and also for feedstock to manufacture spacecraft propellants. The other approach is to extract lattice-bound water and hydroxyl from the minerals that make up the solid grains of rock and regolith. The ultimate intent is to integrate the findings with other efforts, such as, in the creation of complete water-from-ice production systems for various down-stream uses. The project consists of several elements, now in various stages of completion. They are presented here in the approximate order they would generally be applied to a water-extraction system: Digging icy regolith, transporting it, capturing water vapor, and sealing chambers from the outer environment.

L Gertsch↗

NASA NTRSDate not supplied

Fundamental Regolith Properties, Handling and Water Capture (FLEET) Update

regolith excavation↗

NASA NTRS1989

Verification of spatial and temporal pressure distributions in segmented solid rocket motors

A wide variety of analytical tools are in use today to predict the history and spatial distributions of pressure in the combustion chambers of solid rocket motors (SRMs). Experimental and analytical methods are presented here that allow the verification of many of these predictions. These methods are applied to the redesigned space shuttle booster (RSRM). Girth strain-gage data is compared to the predictions of various one-dimensional quasisteady analyses in order to verify the axial drop in motor static pressure during ignition transients as well as quasisteady motor operation. The results of previous modeling of radial flows in the bore, slots, and around grain overhangs are supported by approximate analytical and empirical techniques presented here. The predictions of circumferential flows induced by inhibitor asymmetries, nozzle vectoring, and propellant slump are compared to each other and to subscale cold air and water tunnel measurements to ascertain their validity.

Salita, Mark↗

NASA NTRS2021

Aqua Factorem: Ultra Low Energy Lunar Water Extraction

We propose a new method we call Aqua Factorem to extract lunar water. It will drastically reduce energy and complexity of lunar mining operations helping to establish this industry. Other methods to extract water from the regolith are based on phase change, pumping energy into the regolith to sublimate the ice into vapor, then capturing the vapor, re-freezing it, and hauling the solid ice to a chemical processor where it is converted again into vapor for purification then electrolysis. This requires transporting high power into the permanently shadowed regions (PSRs) not only to vaporize the ice in situ in the soil but to heat the surrounding soil itself, which is wasted energy. Still other methods are based on strip mining and hauling the resource along with slag (the unwanted silicates, which constitutes about 95% of the mass), to a processing unit that is located outside the PSRs. That may be a simpler architecture but is generally not favored because hauling 49,000 t of regolith over many kilometers yearly to produce the projected demand of 2,450 t of propellant would be terribly difficult and expensive with high risk that the vehicles will get stuck driving with such loads across the unprepared regolith. We propose an alternative to both of these approaches, taking advantage of the processing that the unique lunar geology has already performed. Micrometeoroid bombardment has already broken most solid material in the upper part of the regolith into fine grains. This includes solid material of all compositions, including the ice, which is as hard as granite at PSR temperatures and is therefore essentially another type of rock. These ice grains are intermixed with all the other minerals, so a simple, ultra-low-energy grain-sorting process can extract the ice without phase change. As another benefit it can extract the 1 wt% free metal known to be in lunar soil, again with very little energy. The ice can then be hauled to the chemical processing unit in solid phase and converted into rocket propellant. We estimate the 800 kW power needed for thermal extraction can be reduced to less than 100 watts using the new method. This affects the entire architecture of the mining operation producing extensive economic benefit, which we will quantify in this study. We will study it in the context of a mission to mine propellants commercially for space tugs that boost commercial communication satellites from Geosynchronous Transfer Orbit (GTO) to Geostationary Orbit (GEO) then return to the lunar surface for refueling. This simple architecture requires the minimum number of in-space elements, and notably does not require an in-space propellant depot, so it provides the lowest cost and lowest risk startup for a commercial operation. The study will also test the innovative Aqua Factorem process through laboratory experiments, and this will produce basic insights into the handling of lunar resources.

lunar↗

NASA NTRS2012

Development and Testing of a Green-Propellant Micro-Hybrid Thruster with Electrostatic Ignition

As early as 1937 German scientists at Peenemunde experimented with highly unstable fuel blends of nitrous oxide (N2O) and ethanol. These early tests mostly resulted in explosions and destroyed rocket engines. More recently several companies have developed experimental nitrous oxide fuel blends (NOFB) with Isp exceeding 300 sec. Although NOFBx has recently been cleared for tests on the International Space Station, this propellant remains highly experimental and has not been cleared for commercial transport by the US DOT. Recent work by Karabeyoglu et al. has raised concerns about the safety risks of mixing hydrocarbons with N2O. Liquid oxidizer/fuel blends are highly explosive and require extreme care in transport and servicing. By adding small amounts of a liquid organic fuel such as alcohol or a hydrocarbon, the odds of an explosive decomposition event are significantly increased.iv The proposed solution mitigates the explosion hazards of NOFB by separating the oxidizer from the hydrocarbon fuel formed as of a small cylindrical section of ABS thermoplastic. As N2O vapor flows across the grain segment, current enters a 1000 VDC high-tension lead in the ABS fuel grain and produces an inductive spark that vaporizes a small amount of the material. The ablated fuel vapor plus residual energy from the spark seed a localized exothermic N2O dissociation that produces sufficient heat to initiate combustion. The process is also effective when gaseous oxygen is used. A low TRL (2-3) prototype demonstrating the feasibility of controlled hydrocarbon-seeding was recently tested at Utah State University.v The unit features a miniature 2.5 cm ABS fuel grain fabricated using a Stratasys Dimension 3-D printer. The 9-N thruster was pulse-fired up to 27 consecutive times on a single ABS grain segment. Ignition was achieved by as little as 12-15 Joules energy input. This value is contrasted with the typical 30-minute pre-heat requirement for the ECAPS LMP-103S ADN-based monopropellant, requiring an energy input of 14,850 Joules for catalytic dissociation. The hydrocarbon-seeded micro-hybrid was also adapted as a non-pyrotechnic ignitor for a 900 N (200-lbf) thrust hybrid motor. The motor was successfully ignited 4 consecutive times with no hardware swaps or propellant additions. The amount of ABS seed material that can be fit into the injector cap is the only limit to the number of available repeat firings. This series of tests marks the first time a hybrid motor was ever ignited by other than a solid-propellant pyrotechnic charge or bi-propellant flame ignitor. Nitrous oxide hybrid motors are typically difficult to ignite and usually require multiple solid-propellant charges to initiate combustion, so this nonpyrotechnic ignition is a significant accomplishment. The controlled hydrocarbon-seeding approach is fundamentally different from all other green propellant solutions offered by the aerospace industry. Although the proposed system is more correctly a hybrid technology; the system retains all the simple features of a monopropellant design. To date no optimization study has been performed to identify the best grain geometry for electrostatic ignition. Fortunately, because the grain segments are fabricated using rapid-prototyping technology, changing the grain geometry is as simple as modifying the 3-D printer CAD-file. Vacuum Isp exceeding 270 seconds has been demonstrated (Ref v), a value significantly higher than those offered by competing green monopropellant options. The propellants of choice, N2O/GOX and ABS are 100% non-toxic, non-explosive, and environmentally benign. Because the inert oxidizer and fuel components are mixed only within the combustion chamber, the system retains the inherent safety of a hybrid rocket and can be piggy-backed as a secondary payload with no overall mission risk increase to the primary payload, an excellent characteristic for secondary launch systems.

Whitmore, Stephen A.↗

NASA NTRS1971

Development of the Algol III solid rocket motor for SCOUT.

The design and performance of a motor developed for the first stage of the NASA SCOUT-D and E launch vehicles are discussed. The motor delivers a 30% higher total impulse and a 35 to 45% higher payload mass capability than its predecessor, the Algol IIB. The motor is 45 in. in diameter, has a length-to-diameter ratio of 8:1 and delivers an average 100,000-lb thrust for an action time of 72 sec. The motor design features a very high volumetrically loaded internal-burning charge of 17% aluminized polybutadiene propellant, a plasma-welded and heat-treated steel alloy case, and an all-ablative plastic nose liner enclosed in a steel shell. The only significant development problem was the grain design tailoring to account for erosive burning effects which occurred in the high-subsonic-Mach-number port. The tests performed on the motor are described.

Felix, B. R.↗

NASA NTRS2012

Correlation of Fracture Behavior With Microstructure in Friction Stir Welded, and Spin Formed AI-Li 2195 Domes

Single-piece, spin-formed domes manufactured from friction stir welded (FSW) plates of Al-Li alloy 2195 have the potential to reduce the cost of fabricating cryogenic propellant tanks. Mechanical properties in the completed domes can be related directly to the final material condition and the microstructures developed. However, these new fabrication techniques have resulted in unexpected material challenges, such as abnormal grain growth in the weld nugget and the propensity for fracture in the adjacent thermo-mechanically affected zone (TMAZ). In this study, the microstructure and texture transformations within the TMAZ are related to fracture location in the vicinity of the weldment. The texture variations in the TMAZ are caused primarily by the varying amounts of shear deformation introduced during the FSW process. Grain morphology and microtexture characteristics are examined as a function of location in the TMAZ via electron backscatter diffraction (EBSD). A strong correlation between fracture location and the presence of texture banding in the TMAZ is observed. The fracture path tends to follow a distinct region of low Taylor Factor (TF) grains.

Tayon, Wesley A.↗

NASA NTRS1993

Development and testing of 11- and 24-inch hybrid motors under the joint government/industry IR&D program

Establishment of a test facility and associated 11-in.-diameter motor for hybrid propulsion technology development at NASA's George C. Marshall Space Flight Center is discussed in this paper. Results of twenty 11-in.-diameter motor tests with a UTF-29901 (60 percent polycyclopentadiene, 40 percent hydroxyl-terminated polybutadiene)/gaseous oxygen propellant system are presented. Tests at this scale have developed fuel regression correlations for comparison with results of yet-to-be-completed, 24-in.-diameter motor tests; demonstrated combustion efficiency levels in the 95 percent range for both single- and multiple-port grain configurations; have shown smooth and stable throttling characteristics over flight-type throttle ranges; and have begun to establish criteria for stable combustion in hybrid motors. The testing of 24-in. motors has not as yet been initiated and is not addressed.

Boardman, T. A.↗

NASA NTRS1993

Test results from a simple, low-cost, pressure-fed liquid hydrogen/liquid oxygen rocket combustor

A simple, low-cost rocket engine was designed, fabricated, and successfully hot fire tested over a wide range of interface conditions and operating parameters. The engine used low enthalpy hydrogen (45 to 70 R, 200 to 390 psia) and oxygen (139 to 163 R, 210 to 480 psia) propellants pressure-fed directly from facility cryogenic tanks. The engine demonstrated excellent performance, with 97% average combustion efficiency, and absence of combustion instabilities. Engine design chamber pressure was 300 psia, yielding about 16,500 pounds thrust at sea level with a 3:1 expansion ration test nozzle. The engine used a fixed-element injector based on TRW's unique coaxial pintle design, but was operated at 60%, 80%, and 100% thrust levels by throttling facility propellant valves. The engine was tested at propellant mixture ratios (O/F) from 5.8 to 8.4; design O/F was 6.6. To document combustion stability, in five tests RDX explosive pulse guns were detonated in radial and tangential directions across the combustion chamber during steady-state operation. The largest disturbance consisted of simultaneous detonation of a 20-grain radial gun and a 40-grain tangential gun. In no case was an instability, either feed system mode or chamber acoustic mode, excited. High-frequency piezoelectric pressure transducers documented stable recovery from disturbance overpressures within 40 milliseconds of peak pressure. A total of 67 firing tests, accumulating 149 seconds of firing time above 10% P(sub c), were performed. Since parametric testing required run durations of only 2 to 3 seconds, a heat sink combustion chamber was employed for most runs. To evaluate the feasibility of a low-cost ablative system for a flight engine design, one 20-second continuous firing was conducted with a silicone rubber chamber/throat/nozzle liner cast in one piece directly into the engine. The ablative engine operated at the equivalent of 309 seconds sea level specific impulse, when adjusted to a 98% efficient 6:1 expansion ration nozzle, and 430 seconds vacuum specific impulse, when adjusted to a 98% efficient 50:1 expansion ratio nozzle. This engine and test series represent an initial subscale demonstration of a new booster-class engine that eliminates the cost and complexity associated with regenerative cooling and typical engine cycles. This paper presents a description of the engine design and discussion and summary data plots of the performance measured during the parametric testing.

Dressler, G. A.↗

NASA NTRS1981

Space Shuttle SRM performance improvement

A number of options for Solid Rocket Motor (SRM) performance improvement were studied and evaluated by NASA with respect to payload improvement potential, technical risk, schedule, cost, and impact on Shuttle system performance. It was found that the SRM delivered specific impulse could be improved by increasing the nozzle expansion ratio from 7.16 to 7.72. This was achieved by decreasing the throat diameter of the nozzle exit cone, while staying within tooling, facility, and ICD limitations. A simple modification of the grain inhibiting pattern was made to reshape the thrust-time history and thereby obtain more delivered impulse during the early portion of motor operation. These performance options, initiated in October 1980, provide a 3,000 lb payload increase. Longer range options are the use of a filament wound composite case, a HTPB propellant, and further increases in the nozzle expansion ratio. These improvements have a potential of 10,000 to 11,000 lb payload increase.

Speak, C. A.↗

NASA NTRS1976

Solid-propellant rocket motor internal ballistic performance variation analysis, phase 2

The Monte Carlo method was used to investigate thrust imbalance and its first time derivative throughtout the burning time of pairs of solid rocket motors firing in parallel. Results obtained compare favorably with Titan 3 C flight performance data. Statistical correlations of the thrust imbalance at various times with corresponding nominal trace slopes suggest several alternative methods of predicting thrust imbalance. The effect of circular-perforated grain deformation on internal ballistics is discussed, and a modified design analysis computer program which permits such an evaluation is presented. Comparisons with SRM firings indicate that grain deformation may account for a portion of the so-called scale factor on burning rate between large motors and strand burners or small ballistic test motors. Thermoelastic effects on burning rate are also investigated. Burning surface temperature is calculated by coupling the solid phase energy equation containing a strain rate term with a model of gas phase combustion zone using the Zeldovich-Novozhilov technique. Comparisons of solutions with and without the strain rate term indicate a small but possibly significant effect of the thermoelastic coupling.

Sforzini, R. H.↗

NASA NTRS1989

Hybrid propulsion technology program: Phase 1, volume 1

A number of booster propulsion system concepts are being considered for the next generation of manned and unmanned space launch vehicles. The one propulsion system concept that has potential for reducing costs with increased safety, reliability, and performance is hybrid propulsion (HP). A HP system may be thought of as a liquid propulsion system with solid fuel or a solid propulsion system with a liquid oxidizer. The liquid propulsion features that are most attractive are the higher specific impulse, clean exhaust, separated propellants, and oxidizer loading just prior to launch. The most attractive solid propulsion features includes low life cycle costs, no rotating machinery, compact size, and a robust case. In addition, a HP system has a robust LO2 tank; provides thrust control for ignition, to alleviate flight loads, and for thrust termination; and uses an inert grain that is not sensitive to anomalies such as cracks, voids, and separations. The object is to develop the technology to enable the application of HP to manned and unmanned space launch vehicles. This program will identify the necessary technology, acquire that technology, and demonstrate that technology. This volume is the executive summary.

Schuler, A. L.↗

NASA NTRS1991

Experimental investigation of a solid rocket combustion simulator

The response of solid rocket motor materials to high-temperature corrosive gases is usually accomplished by testing the materials in a subscale solid rocket motor. While this imposes the proper thermal and chemical environment, a solid rocket motor does not provide practical features that would enhance systematic evaluations such as: the ability to throttle for margin testing, on/off capability, low test cost, and a low-hazards test article. Solid Rocket Combustion Simulators (SRCS) are being evaluated by NASA to test solid rocket nozzle materials and incorporate these essential practical features into the testing of rocket materials. The SRCS is designed to generate the thermochemical environment of a solid rocket. It uses hybrid rocket motor technology in which gaseous oxygen (Gox) is injected into a chamber containing a solid fuel grain. Specific chemicals are injected in the aft mixing chamber so that the gases entering the test section match the temperature and a non-dimensional erosion factor B' to insure similarity with a solid motor. Because the oxygen flow can be controlled, this approach allows margin testing, the ability to throttle, and an on/off capability. The fuel grains are inert which makes the test article very safe to handle. The objective of this work was to establish the baseline operating characteristics of a Labscale Solid Rocket Combustion Simulator (LSRCS). This included establishing the baseline burning rates of plexiglass fuels and the evaluation of a combustion instability for hydroxy-terminated polybutadyene (HTPB) propellants. The scope of the project included: (1) activation of MSFC Labscale Hybrid Combustion Simulator; (2) testing of plexiglass fuel at Gox ranges from 0.025 to 0.200 lb/s; (3) burning HTPB fuels at a Gox rate of 0.200 lb/s using four different mixing chamber configurations; and (4) evaluating the fuel regression and chamber pressure responses of each firing.

Frederick, Robert A., Jr.↗

NASA NTRS1987

A 2000-hour cyclic endurance test of a laboratory model multipropellant resistojet

The technological readiness of a long-life multipropellant resistojet for space station auxiliary propulsion is demonstrated. A laboratory model resistojet made from grain-stabilized platinum served as a test bed to evaluate the design characteristics, fabrication methods, and operating strategies for an engineering model multipropellant resistojet developed under contract by the Rocketdyne Division of Rockwell International and Technion Incorporated. The laboratory model thruster was subjected to a 2000-hr, 2400-thermal-cycle endurance test using carbon dioxide propellant. Maximum thruster temperatures were approximately 1400 C. The post-test analyses of the laboratory model thruster included an investigation of component microstructures. Significant observations from the laboratory model thruster are discussed as they relate to the design of the engineering model thruster.

Morren, W. Earl↗

NASA NTRS1987

2000-hour cyclic endurance test of a laboratory model multipropellant resistojet

Morren, W. Earl↗

NASA NTRS1987

Structure and dynamics of amorphous water ice

Further insight into the structure and dynamics of amorphous water ice, at low temperatures, was obtained by trapping in it Ar, Ne, H2, and D2. Ballistic water-vapor deposition results in the growth of smooth, approximately 1 x 0.2 micrometer2, ice needles. The amorphous ice seems to exist in at least two separate forms, at T < 85 K and at 85 < T < 136.8 K, and transform irreversibly from one form to the other through a series of temperature-dependent metastable states. The channels formed by the water hexagons in the ice are wide enough to allow the free penetration of H2 and D2 into the ice matrix even in the relatively compact cubic ice, resulting in H2-(D2-) to-ice ratios (by number) as high as 0.63. The larger Ar atoms can penetrate only into the wider channels of amorphous ice, and Ne is an intermediate case. Dynamic percolation behavior explains the emergence of Ar and Ne (but not H2 and D2) for the ice, upon warming, in small and big gas jets. The big jets, each containing approximately 5 x 10(10) atoms, break and propel the ice needles. Dynamic percolation also explains the collapse of the ice matrix under bombardment by Ar , at a pressure exceeding 2.6 dyn cm-2, and the burial of huge amounts of gas inside the collapsed matrix, up to an Ar-to-ice of 3.3 (by number). The experimental results could be relevant to comets, icy satellites, and icy grain mantles in dense interstellar clouds.

NASA Program Exobiology↗

NASA NTRS1973

Solid motor aft closure insulation erosion

The erosion rate of aft closure insulation in a number of large solid propellant motors was empirically analyzed by correlating the average ablation rate with a number of variables that had previously been demonstrated to affect heat flux. The main correlating parameter was a heat flux based on the simplified Bartz heat transfer coefficient corrected for two-dimensional effects. A multiplying group contained terms related to port-to-throat ratio, local wall angle, grain geometry and nozzle cant angle. The resulting equation gave a good correlation and is a useful design tool.

Stampfl, E.↗

NASA NTRS2006

New Propellants and Cryofuels

The proposed research will investigate the stability and cryogenic properties of solid propellants that are critical to NASA s goal of realizing practical propellant designs for future spacecraft. We will determine the stability and thermal properties of a solid hydrogen-liquid helium stabilizer in a laboratory environment in order to design a practical propellant. In particular, we will explore methods of embedding atomic species and metallic nano-particulates in hydrogen matrices suspended in liquid helium. We will also measure the characteristic lifetimes and diffusion of atomic species in these candidate cryofuels. The most promising large-scale advance in rocket propulsion is the use of atomic propellants; most notably atomic hydrogen stabilized in cryogenic environments, and metallized-gelled liquid hydrogen (MGH) or densified gelled hydrogen (DGH). The new propellants offer very significant improvements over classic liquid oxygen/hydrogen fuels because of two factors: (1) the high energy-release, and (ii) the density increase per unit energy release. These two changes can lead to significant reduced mission costs and increased payload to orbit weight ratios. An achievable 5 to 10 percent improvement in specific impulse for the atomic propellants or MGH fuels can result in a doubling or tripling of system payloads. The high-energy atomic propellants must be stored in a stabilizing medium such as solid hydrogen to inhibit or delay their recombination into molecules. The goal of the proposed research is to determine the stability and thermal properties of the solid hydrogen-liquid helium stabilizer. Magnetic resonance techniques will be used to measure the thermal lifetimes and the diffusive motions of atomic species stored in solid hydrogen grains. The properties of metallic nano-particulates embedded in hydrogen matrices will also be studied and analyzed. Dynamic polarization techniques will be developed to enhance signal/noise ratios in order to be able to detect low concentrations of the introduced species. The required lifetimes for atomic hydrogen and other species can only be realized at low temperatures to avoid recombination of atoms before use as a fuel.

Palasezski, Bryan↗