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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Performance and heat transfer characteristics of a carbon monoxide/oxygen rocket engine

The combustion and heat transfer characteristics of a carbon monoxide and oxygen rocket engine were evaluated. The test hardware consisted of a calorimeter combustion chamber with a heat sink nozzle and an eighteen element concentric tube injector. Experimental results are given at chamber pressures of 1070 and 3070 kPa, and over a mixture ratio range of 0.3 to 1.0. Experimental C efficiency was between 95 and 96.5 percent. Heat transfer results are discussed both as a function of mixture ratio and axial distance in the chamber. They are also compared to a Nusselt number correlation for fully developed turbulent flow.

Linne, Diane L.↗
NASA NTRS2011

Development of a Pulsed 2-micron Laser Transmitter for CO2 Sensing from Space

NASA Langley Research Center (LaRC), in collaboration with NASA Jet Propulsion Laboratory (JPL), is engaged in the development and demonstration of a highly efficient, versatile, 2-micron pulsed laser that can be used in a pulsed Differential Absorption Lidar (DIAL)/Integrated Path Differential Absorption (IPDA) instrument to make precise, high-resolution CO2 measurements to investigate sources, sinks, and fluxes of CO2. This laser transmitter will feature performance characteristics needed for an ASCENDS system that will be capable of delivering the CO2 measurement precision required by the Earth Science Decadal Survey (DS).

Singh, Upendra N.↗
NASA NTRS2004

Turbomachinery for Low-to-High Mach Number Flight

The thrust capability of turbojet cycles is reduced at high flight Mach number (3+) by the increase in inlet stagnation temperature. The 'hot section' temperature limit imposed by materials technology sets the maximum heat addition and, hence, sets the maximum flight Mach number of the operating envelope. Compressor pre-cooling, either via a heat exchanger or mass-injection, has been suggested as a means to reduce compressor inlet temperature and increase mass flow capability, thereby increasing thrust. To date, however, no research has looked at compressor cooling (i.e., using a compressor both to perform work on the gas path air and extract heat from it simultaneously). We wish to assess the feasibility of this novel concept for use in low-to-high Mach number flight. The results to-date show that an axial compressor with cooling: (1) relieves choking in rear stages (hence opening up operability), (2) yields higher-pressure ratio and (3) yields higher efficiency for a given corrected speed and mass flow. The performance benefit is driven: (i) at the blade passage level, by a decrease in the total pressure reduction coefficient and an increase in the flow turning; and (ii) by the reduction in temperature that results in less work required for a given pressure ratio. The latter is a thermodynamic effect. As an example, calculations were performed for an eight-stage compressor with an adiabatic design pressure ratio of 5. By defining non-dimensional cooling as the percentage of compressor inlet stagnation enthalpy removed by a heat sink, the model shows that a non-dimensional cooling of percent in each blade row of the first two stages can increase the compressor pressure ratio by as much as 10-20 percent. Maximum corrected mass flow at a given corrected speed may increase by as much as 5 percent. In addition, efficiency may increase by as much as 5 points. A framework for characterizing and generating the performance map for a cooled compressor has been developed. The approach is based upon CFD computations and mean line analysis. Figures of merit that characterize the bulk performance of blade passage flows with and without cooling are extracted from CFD solutions. Such performance characterization is then applied to a preliminary compressor design framework (mean line). The generic nature of this approach makes it suitable for assessing the effect of different types of compressor cooling schemes, such as heat exchange or evaporative cooling (mass injection). Future work will focus on answering system level questions regarding the feasibility of compressor cooling. Specifically, we wish to determine the operational parametric space in which compressor cooling would be advantageous over other high flight Mach number propulsion concepts. In addition, we will explore the design requirements of cooled compressor turbomachinery, as well as the flow phenomena that limit and control its operation, and the technology barriers that must be crossed for its implementation.

Tan, Choon S.↗
NASA NTRS2019

Development of a Flight-Worthy 10 to 4 K Continuous Adiabatic Demagnetization Refrigerator

The cryogenics and fluids branch at NASA's Goddard Space Flight Center is currently developing a high-efficiency, vibration-free, flight-worthy Continuous Adiabatic Demagnetization Refrigerator (CADR) that consist of two modular units: one that lifts ~6 microW at 50 mK while rejecting its heat to a 4 K thermal sink, and another unit that provides a constant 4 K cooling stage while rejecting its heat to a thermal sink at 10 K. The two units are linked together via a 4 K common platform. This paper discusses the status report on the thermodynamic performance of the 4 -10 K ADR. This ADR utilizes an Nb3Sn superconducting magnet and Gadolinium Gallium Garnet (GGG) as its refrigerant. Results show that an idealized cycle, one where its hold time at 4 K is equal to the recycle time, can lift 13 mW at 4 K with a hold time of 132 seconds.

CADR↗
NASA NTRS2003

Design and Testing of Non-Toxic RCS Thrusters for Second Generation Reusable Launch Vehicle

The current NASA Space Shuttle auxiliary propulsion system utilizes nitrogen tetroxide (NTO) and monomethylhydrazine (MMH), hypergolic propellants. This use of these propellants has resulted in high levels of maintenance and precautions that contribute to costly launch operations. By employing alternate propellant combinations, those less toxic to humans, the hazards and time required between missions can be significantly reduced. Use of alternate propellants can thereby increase the efficiency and lower the cost in launch operations. In support of NASA's Space Launch Initiative (SLI), TRW proposed a three-phase project structured to significantly increase the technology readiness of a high-performance reaction control subsystem (RCS) thruster using non-toxic propellant for an operationally efficient and reusable auxiliary propulsion system (APS). The project enables the development of an integrated primary/vernier thruster capable of providing dual-thrust levels of both 1000-lbf class thrust and 25-lbf thrust. The intent of the project is to reduce the risk associated with the development of an improved RCS flight design that meets the primary NASA objectives of improved safety and reliability while reducing systems operations and maintenance costs. TRW proposed two non-toxic auxiliary propulsion engine designs, one using liquid oxygen and liquid hydrogen and the other using liquid oxygen and liquid ethanol, as candidates to meet the goals of reliability and affordability at the RCS level. Both of these propellant combinations offer the advantage of a safe environment for maintenance, while at the same time providing adequate to excellent performance for a conventional liquid propulsion systems. The key enabling technology incorporated in both TRW thrusters is the coaxial liquid on liquid pintle injector. This paper will concentrate on only the design and testing of one of the thrusters, the liquid oxygen (LOX) and liquid hydrogen (LH2) thruster. The LOX/LH2 thruster design includes a LOX-centered pintle injector, consisting of two rows of slots that create a radial spoke spray pattern in the combustion chamber. The main fuel injector creates a continuous sheet of LH2 originating upstream of the LOX pintle injector. The two propellants impinge at the pintle slots, where the resulting momentum ratio and spray pattern determines the combustion efficiency and thermal effects on the hardware. Another enabling technology used in the design of this thruster is fuel film cooling through a duct, lining the inner wall of the combustion chamber barrel section. The duct is also acts as a secondary fuel injection point. The variation in the amount of LH2 used for the duct allows for adjustments in the cooling capacity for the thruster. The Non-Toxic LOX-LH2 RCS Workhorse Thruster was tested at the NASA Marshall Space Flight Center's Test Stand 500. Hot-fire tests were conducted between March 08, 2002 and April 05, 2002. All testing during the program base period were performed at sea-level conditions. During the test program, 7 configurations were tested, including 2 combustion chambers, 3 LOX injector pintle tips, and 4 LH2 injector stroke settings. The operating conditions that were surveyed varied thrust levels, mixture ratio and LH2 duct cooling flow. The copper heat sink chamber was used for 16 burns, each burn lasting from 0.4 to 10 seconds, totaling 51.4 seconds, followed by Haynes chamber testing ranging from 0.9 to 120 seconds, totaling 300.9 seconds. The total accumulated burn time for the test program is 352.3 seconds. C* efficiency was calculated and found to be within expectable limits for most operating conditions. The temperature on the Haynes combustion chamber remained below established material limits, with the exception of one localized hot spot. The test results demonstrate that both the coaxial liquid-on-liquid pintle injector design and fuel duct concepts are viable for the intended application. The thruster head-e design maintained cryogenic injection temperatures while firing, which validates the concept for minimal heat soak back. By injecting fuel into the duct, the throat temperatures were manageable, yet the split of fuel through the cooling duct does not compromise the overall combustion efficiency, which indicates that, provided proper design refinement, such a concept can be applied to a high-performance version of the thruster. These hot fire tests demonstrate the robustness of the duct design concept and good capability to withstand off-nominal operating conditions without adversely impacting the thermal response of the engine, a key design feature for a cryogenic thruster.

Calvignac, Jacky↗
NASA NTRS2003

A Compact, Continuous Adiabatic Demagnetization Refrigerator with High Heat Sink Temperature

In the continuous adiabatic demagnetization refrigerator (ADR), the existence of a constant temperature stage attached to the load breaks the link between the requirements of the load (usually a detector array) and the operation of the ADR. This allows the ADR to be cycled much faster, which yields more than an order of magnitude improvement in cooling power density over single-shot ADRs. Recent effort has focused on developing compact, efficient higher temperature stages. An important part of this work has been the development of passive gas-gap heat switches that transition (from conductive to insulating) at temperatures around 1 K and 4 K without the use of an actively heated getter. We have found that by carefully adjusting available surface area and the number of He-3 monolayers, gas-gap switches can be made to operate passively. Passive operation greatly reduces switching time and eliminates an important parasitic heat load. The current four stage ADR provides 6 micro W of cooling at 50 mK (21 micro W at 100 mK) and weighs less than 8 kg. It operates from a 4.2 K heat sink, which can be provided by an unpumped He bath or many commercially available mechanical cryocoolers. Reduction in critical current with temperature in our fourth stage NbTi magnet presently limits the maximum temperature of our system to approx. 5 K. We are developing compact, low-current Nb3Sn magnets that will raise the maximum heat sink temperature to over 10 K.

Shirron, P. J.↗
NASA NTRS1986

Evaluation of active thermal control options for Space Station

An analysis of various Space Station (MSS) active thermal control systems options under consideration because of their potential low weight, efficiency and reliability is reported. The study addressed ordinary and diode-action body mounted radiators, thermal storage, the area and pumping power requirements for single-phase cooling of cold plates, and single-phase and two-phase active cooling loops. The base configuration considered was a core MSS formed by four habitable modules on which are mounted heat pipe radiators articulated to be always edge-on to the sun. A simulation was performed which accounted for the available heat sinks, several thermal loads and the heat rejection capability. No benefits were found with diode-action radiators if the solar absorption is 0.1 or less, although diode-action heat pipes will maintain a higher level of performance in the presence of coating degradation. Thermal storage becomes important only with radiator coating degradation. Water can be up to three times as efficient as Freon as a heat transfer medium. Finally, single-phase cooling offers a lower system mass than two-phase cooling if varying temperature heat loads can be accommodated.

Schuster, J. R.↗
NASA NTRSDate not supplied

Fluid & Thermal Analysis of a Manifold Microchannel Heat Sink

A three-dimensional (3-D) numerical model has been developed to study the fluid flow and heat transfer through a manifold-microchannel (MMC) heat sink, a microfluidic cooling system designed as a heat dissipation solution for compact, high-powered electronic systems. An MMC consists of a 3-D manifold structure that distributes working fluid through alternating inlet and outlet manifold channels that guide the fluid to and from the microchannels, shortening the flow length and thereby, reducing the pressure drop across the system. Wide bandgap semiconductors such as silicon carbide (SiC) are increasingly utilized due to their ability to enable smaller electronic devices and components to operate more efficiently at higher frequencies. These semiconductors can greatly benefit from the MMC, which can extract all the heat produced by compact, high-powered electronics, enabling them to achieve optimal performance. The MMC also utilizes an embedded cooling approach which allows for fabrication directly within SiC-based electronics, resulting in significant mass and weight savings and lower thermal resistance than conventional heat sink designs. This paper outlines the methods used to conduct fluid and thermal analysis of different MMC configurations for flow parameters such as flow rate and inlet flow conditions. This study involves both steady state and transient thermal analysis as a gradually increasing heat flux is applied to the system over time, which is representative of the heat dissipation from the electronics over a given period. Results from the analysis show that the MMC is capable of effectively dissipating heat flux of ~100 W/cm2 while maintaining considerably low pressure drop (< 1 kPa) and thermal resistance (< 1 K/W) for certain single-phase working fluids.

manifold microchannel↗
NASA NTRSDate not supplied

Fluid & Thermal Analysis of a Manifold Microchannel Heat Sink

A three-dimensional (3-D) numerical model has been developed to study the fluid flow and heat transfer through a manifold-microchannel (MMC) heat sink, a microfluidic cooling system designed as a heat dissipation solution for compact, high-powered electronic systems. An MMC consists of a 3-D manifold structure that distributes working fluid through alternating inlet and outlet manifold channels that guide the fluid to and from the microchannels, shortening the flow length and thereby, reducing the pressure drop across the system. Wide bandgap semiconductors such as silicon carbide (SiC) are increasingly utilized due to their ability to enable smaller electronic devices and components to operate more efficiently at higher frequencies. These semiconductors can greatly benefit from the MMC, which can extract all the heat produced by compact, high-powered electronics, enabling them to achieve optimal performance. The MMC also utilizes an embedded cooling approach which allows for fabrication directly within SiC-based electronics, resulting in significant mass and weight savings and lower thermal resistance than conventional heat sink designs. This paper outlines the methods used to conduct fluid and thermal analysis of different MMC configurations for flow parameters such as flow rate and inlet flow conditions. This study involves both steady state and transient thermal analysis as a gradually increasing heat flux is applied to the system over time, which is representative of the heat dissipation from the electronics over a given period. Results from the analysis show that the MMC is capable of effectively dissipating heat flux of ~100 W/cm2 while maintaining considerably low pressure drop (< 1 kPa) and thermal resistance (< 1 K/W) for certain single-phase working fluids.

manifold microchannel↗
DOE OSTI2023

Understanding the Vertical Transport and Removal of Aerosols during Deep Convective Events

Atmospheric aerosols affect the global energy budget by scattering and absorbing sunlight (direct effects) and by changing the microphysical structure, lifetime, and coverage of clouds (indirect effects). Globally, the free troposphere is a major source of nucleation- and Aitken-mode aerosols due to the enhanced new particle formation rates at high altitudes. Recent studies have shown deep convective systems are capable of transporting these small aerosols from the free troposphere to the boundary layer by strong convective downdrafts and weaker downward motions in the stratiform regions. These vertically transported aerosols can grow into cloud condensation nuclei (CCN) and play a significant role in the global climate. During the deep convective processes, existing accumulation-mode aerosols that act as coagulation sinks of smaller particles are also removed by wet scavenging. Compared to the vertical transport of these particles by entrainment mixing, which is slower but more prevalent, the deep convective downdraft processes may be more rapid and efficient in the vertical transport of aerosols. However, most of the current climate models do not include this mechanism as a source of CCN, mainly because the frequency of deep convective events varies significantly with geographic location and thus their contributions to CCN are unpredictable.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2004

Stirling Microregenerators Fabricated and Tested

A mesoscale Stirling refrigerator patented by the NASA Glenn Research Center is currently under development. This refrigerator has a predicted efficiency of 30 percent of Carnot and potential uses in electronics, sensors, optical and radiofrequency systems, microarrays, and microsystems. The mesoscale Stirling refrigerator is most suited to volume-limited applications that require cooling below the ambient or sink temperature. Primary components of the planar device include two diaphragm actuators that replace the pistons found in traditional-scale Stirling machines and a microregenerator that stores and releases thermal energy to the working gas during the Stirling cycle. Diaphragms are used to eliminate frictional losses and bypass leakage concerns associated with pistons, while permitting reversal of the hot and cold sides of the device during operation to allow precise temperature control. Three candidate microregenerators were fabricated under NASA grants for initial evaluation: two constructed of porous ceramic, which were fabricated by Johns Hopkins Applied Physics Laboratory, and one made of multiple layers of nickel and photoresist, which was fabricated by Polar Thermal Technologies. The candidate regenerators are being tested by Johns Hopkins Applied Physics in a custom piezoelectric-actuated test apparatus designed to produce the Stirling refrigeration cycle. In parallel with the regenerator testing, Johns Hopkins is using deep reactive ion etching to fabricate electrostatically driven, comb-drive diaphragm actuators. These actuators will drive the Stirling cycle in the prototype device. The top photograph shows the porous ceramic microregenerators. Two microregenerators were fabricated with coarse pores and two with fine pores. The bottom photograph shows the test apparatus parts for evaluating the microregenerators, including the layered nickel-and-photoresist regenerator fabricated using LIGA techniques.

Moran, Matthew E.↗
DOE OSTI2021

Measurement techniques of thermoelectric devices and modules

Thermoelectric (TE) energy conversion devices are designed based on measured material transport properties. Although an ideal device efficiency can be calculated using the figure of merit, zT, the actual efficiency of a thermoelectric module is smaller and must be measured. TE device performance testing techniques and procedures are reviewed with a focus on energy conversion efficiency. One of the areas that attract less attention in the literature is the transition from basic thermoelectric materials research to the production of modules and devices. The effects of interface layers, diffusion barriers, thermal insulations, and heat sinks are reviewed. Finally, device performance from single couples to standard modules and long-term reliability are discussed.

Wang, Hsin↗
DOE OSTI2021

Joint CO 2 Mole Fraction and Flux Analysis Confirms Missing Processes in CASA Terrestrial Carbon Uptake Over North America

Terrestrial biosphere models (TBMs) play a key role in the detection and attribution of carbon cycle processes at local to global scales and in projections of the coupled carbon-climate system. TBM evaluation commonly involves direct comparison to eddy-covariance flux measurements. This study uses atmospheric CO 2 mole fraction ([CO 2 ]) measured in situ from aircraft and tower, in addition to flux-measurements from summer 2016 to evaluate the CASA TBM. WRF-Chem is used to simulate [CO 2 ] using biogenic CO 2 fluxes from a CASA parameter-based ensemble and CarbonTracker version 2017 (CT2017) in addition to transport and CO 2 boundary condition ensembles. The resulting “super ensemble” of modeled [CO 2 ] demonstrates that the biosphere introduces the majority of uncertainty to the simulations. Both aircraft and tower [CO 2 ] data show that the CASA ensemble net ecosystem exchange (NEE) of CO 2 is biased high (NEE too positive) and identify the maximum light use efficiency E max a key parameter that drives the spread of the CASA ensemble in summer 2016. These findings are verified with flux-measurements. The direct comparison of the CASA flux ensemble with flux-measurements confirms missing sink processes in CASA. Separating the daytime and nighttime flux, we discover that the underestimated net uptake results from missing sink processes that result in overestimation of respiration. NEE biases are smaller in the CT2017 posterior biogenic fluxes, which assimilates observed [CO 2 ]. Flux tower analyses, however, reveal an unrealistic overestimation of nighttime respiration in CT2017 due to the limitation of inversion strategy.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Biological carbon pump estimate based on multidecadal hydrographic data

The transfer of photosynthetically produced organic carbon from surface to mesopelagic waters draws carbon dioxide from the atmosphere. However, current observation-based estimates disagree on the strength of this biological carbon pump (BCP). Earth system models (ESMs) also exhibit a large spread of BCP estimates, indicating limited representations of the known carbon export pathways. Here we use several decades of hydrographic observations to produce a top-down estimate of the strength of the BCP with an inverse biogeochemical model that implicitly accounts for all known export pathways. Our estimate of total organic carbon (TOC) export at 73.4 m (model euphotic zone depth) is 15.00 ± 1.12 Pg C year –1 , with only two-thirds reaching 100 m depth owing to rapid remineralization of organic matter in the upper water column. Partitioned by sequestration time below the euphotic zone, τ, the globally integrated organic carbon production rate with τ > 3 months is 11.09 ± 1.02 Pg C year –1 , dropping to 8.25 ± 0.30 Pg C year –1 for τ > 1 year, with 81% contributed by the non-advective-diffusive vertical flux owing to sinking particles and vertically migrating zooplankton. Nevertheless, export of organic carbon by mixing and other fluid transport of dissolved matter and suspended particles remains regionally important for meeting the respiratory carbon demand. Here, the temperature dependence of the sequestration efficiency inferred from our inversion suggests that future global warming may intensify the recycling of organic matter in the upper ocean, potentially weakening the BCP.

58 GEOSCIENCES↗
DOE OSTI2020

Anaerobic guilds responsible for mercury methylation in boreal wetlands of varied trophic status serving as either a methylmercury source or sink

Wetlands are common sites of active Hg methylation by anaerobic microbes; however, the amount of methylmercury produced varies greatly, as Hg methylation is dependent upon both the availability of Hg and the composition and activity of the microbial community involved. In this study, we identified the major microbial guilds responsible for Hg methylation along a trophic gradient composed of two sites and three different types of wetlands: a bog–fen peatland gradient and a black alder swamp, serving as net sources and a sink for methylmercury respectively. Iron-reducing bacteria in the Geobacteraceae were important Hg methylators across all wetlands and seasons examined, as evidenced by abundant 16S rRNA and hgcA transcripts clustering with this family. Molybdate inhibited Hg methylation more efficiently in the peatlands than in the swamp, suggesting an increasing role of sulfate-reducing bacteria and/or related syntrophs in the methylation of Hg with decreasing trophic status. Further, sulfate addition failed to increase Hg methylation rates in the peatlands, suggesting that SRBs/syntrophs were instead likely metabolizing alternative substrates such as syntrophic fermentation of organic compounds with methanogens. These results highlight the interconnectivity of anaerobic metabolism and importance of community dynamics on the methylation of Hg in wetlands with different trophic status.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2012

Experimental Investigation of Transient Sublimator Performance

Sublimators have been used as heat rejection devices for a variety of space applications including the Apollo Lunar Module and the Extravehicular Mobility Unit (EMU). Sublimators typically operate with steady-state feedwater utilization at or near 100%. However, sublimators are currently being considered for operations in a cyclical topping mode, which represents a new mode of operation for sublimators. Sublimators can be used as a supplemental heat rejection device during mission phases where the environmental temperature or heat rejection requirement changes rapidly. This scenario may occur during low lunar orbit, low earth orbit, or other planetary orbits. In these mission phases, the need for supplemental heat rejection will vary between zero and some fraction of the overall heat load. In particular, supplemental heat rejection is required for the portion of the orbit where the radiative sink temperature exceeds the system setpoint temperature. This paper will describe the effects of these transient starts and stops on the feedwater utilization during various feedwater timing scenarios. Experimental data from various scenarios is analyzed to investigate feedwater consumption efficiency under the cyclical conditions. Start up utilization tests were conducted to better understand the transient performance. This paper also provides recommendations for future sublimator design and transient operation.

Sheth, Rubik B.↗
DOE OSTI2020

Assessing Impacts of Plant Stoichiometric Traits on Terrestrial Ecosystem Carbon Accumulation Using the E3SM Land Model

Carbon (C) enters into the terrestrial ecosystems via photosynthesis and cycles through the system together with other essential nutrients (i.e., nitrogen [N] and phosphorus [P]). Such a strong coupling of C, N, and P leads to the theoretical prediction that limited nutrient availability will limit photosynthesis rate, plant growth, and future terrestrial C dynamics. However, the lack of reliable information about plant tissue stoichiometric constraints remains a challenge for quantifying nutrient limitations on projected global C cycling. In this study, we harmonized observed plant tissue C:N:P stoichiometry from more than 6,000 plant species with the commonly used plant functional type framework in global land models. Using observed C:N:P stoichiometry and the flexibility of these ratios as emergent plant traits, we show that observationally constrained fixed plant stoichiometry does not improve model estimates of present-day C dynamics compared with unconstrained stoichiometry. However, adopting stoichiometric flexibility significantly improves model predictions of C fluxes and stocks. The 21st century simulations with RCP8.5 CO 2 concentrations show that stoichiometric flexibility, rather than baseline stoichiometric ratios, is the dominant controller of plant productivity and ecosystem C accumulation in modeled responses to CO 2 fertilization. The enhanced nutrient limitations and plant P use efficiency mainly explain this result. This study is consistent with the previous consensus that nutrient availability will limit xfuture land carbon sequestration but challenges the idea that imbalances between C and nutrient supplies and fixed stoichiometry limit future land C sinks. We show here that it is necessary to represent nutrient stoichiometric flexibility in models to accurately project future terrestrial ecosystem carbon sequestration.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2003

Design and Testing of Non-Toxic RCS Thrusters for Second Generation Reusable Launch Vehicle

Under NASA sponsorship, Northrop Grumman Space Technology (NGST) designed, built and tested two non-toxic, reaction control engines, one using liquid oxygen (LOX) and liquid hydrogen (LH2) and the other using liquid oxygen and ethanol. This paper presents the design and testing of the LOX/LH2 thruster. The two key enabling technologies are the coaxial liquid-on-liquid pintle injector and the fuelcooling duct. The workhorse thruster was hotfire tested at the NASA Marshall Space Flight Center Test Stand 500 in March and April of 2002. All tests were performed at sea-level conditions. During the test program, 7 configurations were tested, including 2 combustion chambers, 3 LOX injector pintle tips, and 4 LHp injector settings. The operating conditions surveyed were 70 to 100% thrust levels, mixture ratios from 3.27 to 4.29, and LH2 duct cooling from 18.0 to 25.5% fuel flow. The copper heat sink chamber was used for 16 burns, each burn lasting from 0.4 to 10 seconds, totaling 51.4 seconds, followed by Haynes chamber testing ranging from 0.9 to 120 seconds, totaling 300.9 seconds. The performance of the engine reached 95% C* efficiency. The temperature on the Haynes chamber remained well below established material limits, with the exception of one localized hot spot. These results demonstrate that both the coaxial liquid-on-liquid pintle injector design and fuel duct concepts are viable for the intended application. The thruster headend design maintained cryogenic injection temperatures while firing, which validates the selected injector design approach for minimal heat soak-back. Also, off -nominal operation without adversely impacting the thermal response of the engine showed the robustness of the duct design, a key design feature for this application. By injecting fuel into the duct, the throat temperatures are manageable, yet the split of fuel through the cooling duct does not compromise the overall combstion efficiency, which indicates that, provided proper design refinement, such a concept could be applied to a high-performance version of the thruster.

Calvignac, Jacky↗