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During the 2019 summer term, the author worked with a group of four interns to complete the preliminary design of a 2nd stage solid rocket motor for Up Aerospace’s Spyder Launch Vehicle. The Spyder vehicle is a four stage, solid fuel rocket designed as part of collaboration between NASA and Up Aerospace to develop a vehicle capable of delivering a 10 kg, 6U CubeSat into a 350 km, circular, low Earth orbit. As part of the agreement, NASA is tasked with designing high performance 2nd, 3rd, and 4th stages while Up Aerospace will provide the 1st stage, derived from the first stage of the company’s sub-orbital Spaceloft XL vehicle. Previous intern teams have designed the 3rd and 4th stages, which left the preliminary design of the 2nd stage motor to be completed this summer. The purpose of this report is to highlight a trade study which the author conducted to determine the nozzle geometry which would most benefit the performance of the 2nd stage motor. In this study, various nozzle parameters such as throat radius (RSI), expansion ratio, mass and their effects on the Isp and Delta V of the 2nd Stage were investigated. From this study, a nozzle geometry providing the necessary performance was chosen and implemented as part of the preliminary design of the 2nd stage motor. To mature the 2nd stage motor design, a trade space was needed to determine the nozzle configuration which would most benefit the performance of the 2nd stage. The trade space established did not only evaluate different expansion ratios for the same throat radius, but also investigated the possible performance gained from decreasing the throat radius to increase the expansion ratio and Isp capable of being delivered by the nozzle. Decreasing the throat radius would cause the chamber pressure to increase, consequently increasing the case and insulation mass required to safely operate a motor at higher pressures. To account for this factor, accurate estimates of inert mass first needed to be established. After doing so, the effects of varying nozzle expansion ratios, exit half angles, and subsequently length and mass were evaluated against motor and nozzle performance factors such as delta V and Isp. For this study, four throat radii ranging from 1.75” to 2.375” and consequently four different chamber pressures ranging 550 psia to 1200 psia were investigated. BACKGROUND To launch into Low Earth Orbit, a payload needs to be accelerated to the orbital velocity necessary to keep it from falling back to Earth. The change in velocity required between launch and orbital insertion is known as Delta V. The Delta V which a rocket or stage can deliver can be calculated using the Ideal Rocket equation, 𝛥𝑉=−𝑔0∗𝐼𝑠𝑝∗ln(𝑀𝑓𝑀𝑖) (3) Where 𝑔0 is the acceleration due to gravity at the earth’s surface, 𝐼𝑠𝑝 is the specific impulse of the rocket, 𝑀𝑖 is the initial mass of the rocket, and 𝑀𝑓 is the final mass of the rocket after burnout. From preliminary calculations beyond the scope of this paper, it was determined that 30500 ft/s of delta V would be required for a payload to be inserted into a 350 km circular orbit around the Earth. Using the known masses and Isp values of the 1st, 3rd, and 4th stages and equation 3, the delta V of each stage was calculated. The delta V required by the 2nd stage could then be found by taking the difference between the total delta V required and the delta V of the 1st, 3rd, and 4th stages. From this, the required delta V of the 2nd Stage was calculated to be 7340 ft/s. Specific impulse is an efficiency factor of the nozzle which defines the impulse delivered by the motor per unit of propellant weight. The main variables of a nozzle’s specific impulse investigated in this trade were exit cone half angle, throat radius, and expansion ratio which is affected by the throat radius. The expansion ratio, ε, of a nozzle is defined as the ratio between the nozzle exit area and throat area, and can be calculated using the equation, ε=𝑅𝑒𝑥𝑖𝑡2𝑅𝑠𝑖2 (2) Where 𝑅𝑒𝑥𝑖𝑡 is the radius of the nozzle’s exit and 𝑅𝑠𝑖 is the radius of the nozzle’s throat. A larger expansion ratio and smaller exit half angle will increase the Isp of a nozzle by allowing the gas to expand more and by allowing more of the exhaust gas to produce thrust in the direction of the motor’s central axis. A cross section view of the 2nd Stage motor with the major components annotated is provided in figure 1.
The problem of trajectory optimization is important in all space missions. The solution of this problem enables one to specify the optimum thrust steering program which should be followed to achieve a specified mission objective, simultaneously satisfying the constraints.1 It is well known that whether or not the ascent trajectory is optimal can have a significant impact on propellant usage for a given payload, or on payload weight for the same gross vehicle weight.2 Consequently, ascent guidance commands are usually optimized in some fashion. Multi-stage vehicles add complexity to this analysis process as changes in vehicle properties in one stage propagate to the other stages through gear ratios and changes in the optimal trajectory. These effects can cause an increase in analysis time as more variables are added and convergence of the optimizer to system closure requires more analysis iterations. In this paper, an approach to simplifying this multi-stage problem through the creation of an upper stage capability boundary is presented. This work was completed as part of a larger study focused on trade space exploration for the advanced booster system that will eventually form a part of NASA s new Space Launch System.3 The approach developed leverages Design of Experiments and Surrogate Modeling4 techniques to create a predictive model of the SLS upper stage performance. The design of the SLS core stages is considered fixed for the purposes of this study, which results in trajectory parameters such as staging conditions being the only variables relevant to the upper stage. Through the creation of a surrogate model, which takes staging conditions as inputs and predicts the payload mass delivered by the SLS upper stage to a reference orbit as the response, it is possible to identify a "surface" of staging conditions which all satisfy the SLS requirement of placing 130 metric tons into low-Earth orbit (LEO).3 This identified surface represents the 130 metric ton capability boundary for the upper stage, such that if the combined first stage and boosters can achieve any one staging point on that surface, then the design is identified as feasible. With the surrogate model created, design and analysis of advanced booster concepts is streamlined, as optimization of the upper stage trajectory is no longer required in every design loop.
Traditional azimuth-elevation ("az-el") stages are used to point a variety of devices ranging from large optical telescopes to tank guns. Such a stage typically has an elevation stage having a horizontal axis mounted on an azimuth stage with a vertical axis. Both stages are often motorized. Optical communications transceivers often require two-axis motorized control, as when the communications link is between a ground station and an aircraft or satellite. In such applications, the traditional azimuth-elevation stage has two important drawbacks: a gimbal lock exclusion zone at zenith and susceptibility to pointing errors caused by backlash. Az-el stages in which the azimuth stage cannot rotate a full 360deg have the additional drawback of an azimuth exclusion zone. The diagonal-axes stage described here mitigates or eliminates all of these problems. Instead of one vertical axis and one horizontal axis, a diagonal-axes stage has two horizontal axes, both oriented at 45 to the trajectory of the target. For example, a ground station located on the equator tracking a satellite with an equatorial orbit would have one axis parallel to northeast and southwest, and the other axis parallel to northwest and southeast. The diagonal-axes stage is considerably less vulnerable to backlash. If it is correctly oriented, its axes rotate in only one direction during an overhead pass by a satellite. As a result, the effects of backlash may be inherently eliminated. If the gravity-induced torque on either axis changes during the pass, then backlash may become important during the part of the pass where the gravity torque, instead of opposing the motion of the stage, pushes the stage in the direction of motion. This can result in the loss of gear-to-gear contact in one or more stages of the gear reduction mechanism. In this case, a preload spring used to eliminate backlash need only be sufficiently strong to overcome the gravity torque, i.e. it need not overcome friction in the gear train. The diagonal-axes stage is not backlash-free for arbitrary target trajectories such as an aircraft might execute. If properly oriented for any particular satellite, however, it is backlash-free for all passes of that satellite, which will trace out parallel paths on the sky, and for all passes of any other satellite that are perpendicular to the first. It will also be backlash-free for some fraction of other satellite trajectories.
This viewgraph presentation describes the modeling and simulation of the Ares Upper Stage Transportation, lifting, stacking, and mating operations within the Vehicle Assembly Building (VAB) at Kennedy Space Center (KSC). An aerial view of KSC Launch Shuttle Complex, two views of the Delmia process control layout, and an upper stage move subroutine and breakdown are shown. An overhead image of the VAB and the turning basin along with the Pegasus barge at the turning basin are also shown. This viewgraph presentation also shows the actual design and the removal of the mid-section spring tensioners, the removal of the AFT rear and forward tensioners tie downs, and removing the AFT hold down post and mount. US leaving the Pegasus Barge, the upper stage arriving at transfer aisle, upper stage receiving/inspection in transfer aisle, and an overhead view of upper stage receiving/inspection in transfer aisle are depicted. Five views of the actual connection of the cabling to the upper stage aft lifting hardware are shown. The upper stage transporter forward connector, two views of the rotation horizontal to vertical, the disconnection of the rear bolt ring cabling, the lowering of the upper stage to the inspection stand, disconnection of the rear bolt ring from the upper stage, the lifting of the upper stage and inspection of AFT fange, and the transfer of upper stage in an integrated stack are shown. Six views of the mating of the upper stage to the first stage are depicted. The preparation, inspection, and removal of the forward dome are shown. The upper stage mated on the integrated stack and crawler is also shown. This presentation concludes with A Rapid Upper Limb Assessment (RULA) utilizing male and female models for assessing risk factors to the upper extremities of human beings in an actual physical environment.
A program was conducted to evaluate the effects of scaling, tip clearance, and IGV reset on the performance of a low aspect ratio compressor stage. Stage design was obtained by scaling an existing single stage compressor by a linear factor of 0.304. The design objective was to maintain the meanline velocity field of the base machine in the smaller size. Adjustments were made to account for predicted blockage differences and to chord lengths and airfoil edge radii to obtain reasonable blade geometries. Meanline velocity diagrams of the base stage were not maintained at the scaled size. At design speed and flowrate the scaled stage achieved a pressure ratio of 1.423, adiabatic efficiency of 0.822, and surge margin of 18.5%. The corresponding performance parameters for the base stage were 1.480, 0.872, and 25.2%, respectively. The base stage demonstrated a peak efficiency at design speed of 0.872; the scaled stage achieved a level of 0.838. When the scaled stage rotor and stator tip clearances were doubled, the stage achieved a pressure ratio of 1.413, efficiency of 0.799, and surge margin of 16.0% at the design flowrate. The peak stage efficiency at design speed was 0.825 with the increased clearance. Increased prewhirl lowered the stage pressure ratio as expected. Stage efficiency was maintained with ten degrees of increased prewhirl and then decreased substantially with ten additional degrees of reset.
Two- and three-stage (second stage expendable) shuttle vehicles, both having a hydrogen-fueled, turboramjet-powered first stage, are compared with a two-stage, VTOHL, all-rocket shuttle in terms of payload fraction, inert weight, development cost, operating cost, and total cost. All of the vehicles place 22,680 kilograms of payload into a 500-kilometer orbit. The upper stage(s) uses hydrogen-oxygen rockets. The effect on payload fraction and vehicle inert weight of methane and methane-FLOX as a fuel-propellant combination for the three-stage vehicle is indicated. Compared with a rocket first stage for a two-stage shuttle, an airbreathing first stage results in a higher payload fraction and a lower operating cost, but a higher total cost. The effect on cost of program size and first-stage flyback is indicated. The addition of an expendable rocket second stage (three-stage vehicle) improves the payload fraction but is unattractive economically.
In January 2004, President Bush gave the National Aeronautics and Space Administration (NASA) a vision for Space Exploration by setting our sight on a bold new path to go back to the Moon, then to Mars and beyond. In response to this vision, NASA started the Constellation Program, which is a new exploration launch vehicle program. The primary mission for the Constellation Program is to carry out a series of human expeditions ranging from Low Earth Orbit to the surface of Mars and beyond for the purposes of conducting human exploration of space, as specified by the Vision for Space Exploration (VSE). The intent is that the information and technology developed by this program will provide the foundation for broader exploration activities as our operational experience grows. The ARES I Crew Launch Vehicle (CLV) has been designated as the launch vehicle that will be developed as a "first step" to facilitate the aforementioned human expeditions. The CLV Project is broken into four major elements: First Stage, Upper Stage Engine, Upper Stage (US), and the Crew Exploration Vehicle (CEV). NASA's Marshall Space Flight Center (MSFC) is responsible for the design of the CLV and has the prime responsibility to design the upper stage of the vehicle. The US is the second propulsive stage of the CLV and provides CEV insertion into low Earth orbit (LEO) after separation from the First Stage of the Crew Launch Vehicle. The fully integrated Upper Stage is a mix of modified existing heritage hardware (J-2X Engine) and new development (primary structure, subsystems, and avionics). The Upper Stage assembly is a structurally stabilized cylindrical structure, which is powered by a single J-2X engine which is developed as a separate Element of the CLV. The primary structure includes the load bearing liquid hydrogen (LH2) and liquid oxygen (LOX) propellant tanks, a Forward Skirt, the Intertank structure, the Aft Skirt and the Thrust Structure. A Systems Tunnel, which carries fluid and electrical power functions to other Elements of the CLV, is included as secondary structure. The MSFC has an overall responsibility for the integrated US element as well as structural design an thermal control of the fuel tanks, intertank, interstage, avionics, main propulsion system, Reaction Control System (RCS) for both the Upper Stage and the First Stage. MSFC's Spacecraft and Vehicle Department, Structural and Analysis Design Division is developing a set of predicted mass of these elements. This paper details the methodology, criterion and tools used for the preliminary mass predictions of the upper stage structural assembly components. In general, weight of the cylindrical barrel sections are estimated using the commercial code Hypersizer, whereas, weight of the domes are developed using classical solutions. HyperSizer is software that performs automated structural analysis and sizing optimization based on aerospace methods for strength, stability, and stiffness. Analysis methods range from closed form, traditional hand calculations repeated every day in industry to more advanced panel buckling algorithms. Margin-of-safety reporting for every potential failure provides the engineer with a powerful insight into the structural problem. Optimization capabilities include finding minimum weight panel or beam concepts, material selections, cross sectional dimensions, thicknesses, and lay-ups from a library of 40 different stiffened and sandwich designs and a database of composite, metallic, honeycomb, and foam materials. Multiple different concepts (orthogrid, isogrid, and skin stiffener) were run for multiple loading combinations of ascent design load with and with out tank pressure as well as proof pressure condition. Subsequently, selected optimized concept obtained from Hypersizer runs was translated into a computer aid design (CAD) model to account for the wall thickness tolerance, weld land etc for developing the most probable weight of the components. The flow diram summarizes the analysis steps used in developing these predicted mass.
The Equinox Ocean Turbines (EQOT) current energy converter has a unique design with power generation in two small-diameter turbines attached to the tips of a large-diameter passive rotor. This configuration offers some key advantages for capturing ocean currents. With no centrally placed generator, almost no reaction torque is required at the nacelle of the main large-diameter rotor, and the small-diameter tip turbine generators operate at a higher speed and lower torque. The physics that determine the performance and loads on the turbine are also unique. The interactions of the flow field between the two stages and the general architecture of the system cannot be captured with traditional mid-fidelity modeling tools. For design iterations and large sets of load cases, it is important to have mid-fidelity models that can capture the important phenomenon with enough accuracy to identify global trends. This work uses a limited set of high-fidelity computational fluid dynamics (CFD) simulations to help inform the selection of and construction of a custom mid-fidelity model. Mid-fidelity modeling approaches were verified by comparing key turbine performance quantities to those found with the CFD model. Hydrodynamic interactions of the two-stage rotor were identified through high-fidelity CFD modeling. This highlighted the impact of the main rotor tip vortex and wake on the secondary rotor apparent inflow. This results in a relative flow rotation and sharp deficit, that change the optimal secondary rotor rotation speed and adds unsteadiness to the blade loading respectively. Multiple mid-fidelity approaches were evaluated for their ability to capture these effects. A simple approximation of the combined-stage performance based on single-stage BEM provides a reasonable rough prediction, especially near the peak TSR values, with some larger discrepancy at higher TSRs. Predicting the combined-stage performance based on single-stage CFD data improves this prediction across the TSR range. Although the combined-stage modeling in OLAF was not successful in this stage of the project, it showed promise as a mid-fidelity method, assuming the parameters can be tuned to account for the significant differences in time and length scales between the main and secondary rotors. This may be addressed through code changes in future work. A significant finding from the OLAF work was the agreement between the vortex core radius values found independently via a parameter space search and via CFD. The technique of using single-stage secondary rotor BEM, with a custom inflow taken from single-stage main rotor CFD or OLAF, provides an efficient method to capture one-way coupled flow interactions. This method provided generally good predictions of the impact of the flow rotation on the secondary rotor but struggled to accurately predict the peaks of the unsteady load progression. Future work could include some superposition of a tuned main rotor trailing edge viscous wake into the custom inflow to better predict this interaction.
An experimental investigation was conducted with an 0.8 hub/tip ratio, single-stage, axial flow compressor to determine the potential of tandem-airfoil blading for improving the efficiency and stable operating range of compressor stages. The investigation included testing of a baseline stage with single-airfoil blading and two tandem-blade stages. The overall performance of the baseline stage and the tandem-blade stage with a 20-80% loading split was considerably below the design prediction. The other tandem-blade stage, which had a rotor with a 50-50% loading split, came within 4.5% of the design pressure rise (delta P(bar)/P(bar) sub 1) and matched the design stage efficiency. The baseline stage with single-airfoil blading, which was designed to account for the actual rotor inlet velocity profile and the effects of axial velocity ratio and secondary flow, achieved the design predicted performance. The corresponding tandem-blade stage (50-50% loading split in both blade rows) slightly exceeded the design pressure rise but was 1.5 percentage points low in efficiency. The tandem rotors tested during both phases demonstrated higher pressure rise and efficiency than the corresponding single-airfoil rotor, with identical inlet and exit airfoil angles.
Metallized propellants are liquid propellants with a metal additive suspended in a gelled fuel or oxidizer. Typically, aluminum particles are the metal additives. These propellants provide increase in the density and/or the specific impulse of the propulsion system. Using metallized propellants for volume- and mass-constrained upper stages can deliver modest increases in performance for Low Earth Orbit to Geosynchronous Earth Orbit and other Earth orbital transfer missions. Metallized propellants, however, can enable very fast planetary missions with a single-stage upper stage system. Trade studies comparing metallized propellant stage performance with non-metallized upper stages and the Inertial Upper Stage are presented. These upper stages are both one- and two-stage vehicles that provide the added energy to send payloads to altitudes and onto trajectories that are unattainable with only the launch vehicle. The stage designs are controlled by the volume and the mass constraints of the Space Transportation System and Space Transportation System-Cargo launch vehicles. The influences of the density and specific impulse increases enabled by metallized propellants are examined for a variety of different stage and propellant combinations.
Metallized propellants are liquid propellants with a metal additive suspended in a gelled fuel or oxidizer. Typically, aluminum (Al) particles are the metal additive. These propellants provide increase in the density and/or the specific impulse of the propulsion system. Using metallized propellant for volume-and mass-constrained upper stages can deliver modest increases in performance for low earth orbit to geosynchronous earth orbit (LEO-GEO) and other earth orbital transfer missions. Metallized propellants, however, can enable very fast planetary missions with a single-stage upper stage system. Trade studies comparing metallized propellant stage performance with non-metallized upper stages and the Inertial Upper Stage (IUS) are presented. These upper stages are both one- and two-stage vehicles that provide the added energy to send payloads to altitudes and onto trajectories that are unattainable with only the launch vehicle. The stage designs are controlled by the volume and the mass constraints of the Space Transportation System (STS) and Space Transportation System-Cargo (STS-C) launch vehicles. The influences of the density and specific impulse increases enabled by metallized propellants are examined for a variety of different stage and propellant combinations.
Metallized propellants are liquid propellants with a metal additive suspended in a gelled fuel. Typically, aluminum particles are the metal additive. These propellants increase the density and/or the specific impulse of the propulsion system. Using metallized propellants for volume- and mass-constrained upper stages can deliver modest increases in performance for low Earth orbit to geosynchronous Earth orbit (LEO-GEO) and other Earth-orbital transfer missions. However, using metallized propellants for planetary missions can deliver great reductions in flight time with a single-stage, upper-stage system. Tradeoff studies comparing metallized propellant stage performance with nonmetallized upper stages and the Inertial Upper Stage (IUS) are presented. These upper stages, launched from the STS and STS-C, are both one- and two-stage vehicles that provide the added energy to send payloads to high altitude orbits and onto interplanetary trajectories that are unattainable with only the Space Transportation System (STS) and the Space Transportation System-Cargo (STS-C). The stage designs are controlled by the volume and the mass constraints of the STS and STS-C launch vehicles. The influences of the density and specific impulse increases enabled by metallized propellants are examined for a variety of different stage and propellant combinations.
The object of this design class was to design an earth-to orbit vehicle to replace the present NASA space shuttle. The major motivations for designing a new vehicle were to reduce the cost of putting payloads into orbit and to design a vehicle that could better service the space station with a faster turn-around time. Another factor considered in the design was that near-term technology was to be used. Materials, engines and other important technologies were to be realized in the next 10 to 15 years. The first concept put forth by NASA to meet these objectives was the National Aerospace Plane (NASP). The NASP is a single-stage earth-to-orbit air-breathing vehicle. This concept ran into problems with the air-breathing engine providing enough thrust in the upper atmosphere, among other things. The solution of this design class is a two-stage-to-orbit vehicle. The first stage is air-breathing and the second stage is rocket-powered, similar to the space shuttle. The second stage is mounted on the top of the first stage in a piggy-back style. The vehicle takes off horizontally using only air-breathing engines, flies to Mach six at 100,000 feet, and launches the second stage towards its orbital path. The first stage, or booster, will weigh approximately 800,000 pounds and the second stage, or orbiter will weigh approximately 300,000 pounds. The major advantage of this design is the full recoverability of the first stage compared with the present solid rocket booster that are only partially recoverable and used only a few times. This reduces the cost as well as providing a more reliable and more readily available design for servicing the space station. The booster can fly an orbiter up, turn around, land, refuel, and be ready to launch another orbiter in a matter of hours.
A catalytic combustor (14) includes a first catalytic stage (30), a second catalytic stage (40), and an oxidation completion stage (49). The first catalytic stage receives an oxidizer (e.g., 20) and a fuel (26) and discharges a partially oxidized fuel/oxidizer mixture (36). The second catalytic stage receives the partially oxidized fuel/oxidizer mixture and further oxidizes the mixture. The second catalytic stage may include a passageway (47) for conducting a bypass portion (46) of the mixture past a catalyst (e.g., 41) disposed therein. The second catalytic stage may have an outlet temperature elevated sufficiently to complete oxidation of the mixture without using a separate ignition source. The oxidation completion stage is disposed downstream of the second catalytic stage and may recombine the bypass portion with a catalyst exposed portion (48) of the mixture and complete oxidation of the mixture. The second catalytic stage may also include a reticulated foam support (50), a honeycomb support, a tube support or a plate support.
The Ares I-X flight test provided NASA with the opportunity to test hardware and gather critical data to ensure the success of future Ares I flights. One of the primary test flight objectives was to evaluate the environment during First Stage separation to better understand the conditions that the J-2X second stage engine will experience at ignition [1]. A secondary objective was to evaluate the effectiveness of the stage separation motors. The Ares I-X flight test vehicle was successfully launched on October 29, 2009, achieving most of its primary and secondary test objectives. Ground based video camera recordings of the separation event appeared to show recontact of the First Stage and the Upper Stage Simulator followed by an unconventional tumbling of the Upper Stage Simulator. Closer inspection of the videos and flight test data showed that recontact did not occur. Also, the motion during staging was as predicted through CFD analysis performed during the Ares I-X development. This paper describes the efforts to reconstruct the vehicle dynamics and loads through the staging event by means of a time integrated simulation developed in TREETOPS, a multi-body dynamics software tool developed at NASA [2]. The simulation was built around vehicle mass and geometry properties at the time of staging and thrust profiles for the first stage solid rocket motor as well as for the booster deceleration motors and booster tumble motors. Aerodynamic forces were determined by models created from a combination of wind tunnel testing and CFD. The initial conditions such as position, velocity, and attitude were obtained from the Best Estimated Trajectory (BET), which is compiled from multiple ground based and vehicle mounted instruments. Dynamic loads were calculated by subtracting the inertial forces from the applied forces. The simulation results were compared to the Best Estimated Trajectory, accelerometer flight data, and to ground based video.