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NASA NTRS2017

DSMC simulations of the Shuttle Plume Impingement Flight EXperiment(SPIFEX)

During orbital maneuvers and proximity operations, a spacecraft fires its thrusters inducing plume impingement loads, heating and contamination to itself and to any other nearby spacecraft. These thruster firings are generally modeled using a combination of Computational Fluid Dynamics (CFD) and DSMC simulations. The Shuttle Plume Impingement Flight EXperiment(SPIFEX) produced data that can be compared to a high fidelity simulation. Due to the size of the Shuttle thrusters this problem was too resource intensive to be solved with DSMC when the experiment flew in 1994.

Stewart, Benedicte↗

NASA NTRSDate not supplied

International Space Station Bipropellant Plume Contamination Model Update for Short Thruster Pulse Widths

The International Space Station (ISS) Bipropellant Plume Contamination Model has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS but was not intended to be used for very short thruster pulse widths. This paper presents an updated model that ensures full start-up and shut-down phases are modeled for each thruster firing, when the majority of liquid phase contaminant mass is released. The updated ISS Bipropellant Plume Contamination Model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations and provides a way to take advantage of thruster start-up and shut-down data performance data gathered during thruster test programs, if available. The International Space Station (ISS) Bipropellant Plume Contamination Model developed by Boeing Space Environments is a semi-empirical model anchored in flight experiment data and has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS.[1] The current model utilizes flight experiment data from the Plume Impingement Contamination (PIC) and Shuttle Plume Impingement Flight Experiment (SPIFEX) studies, which include Orbiter 3870 N Primary Reaction Control System (PRCS) and Russian 130 N thrusters operating in pulse mode with 80-100 ms.[2] As the next generation of crew and cargo visiting vehicles are developed and arrive at ISS, minimum pulse widths of vehicle thrusters used for ISS proximity operations have decreased significantly below 80 ms. An update to the ISS Bipropellant Contamination Model is needed to prevent potential under-prediction of thruster plume-induced contamination for these very short pulse widths. Contamination due to thruster plumes occurs in the liquid phase (i.e., unburned or partially burned propellant in the plume). Liquid phase releases primarily occur during thruster start-up and shut-down phases, with the steady state phase contributing a small amount to the total contaminant mass released. The current ISS Bipropellant Plume Contamination Model includes functional dependencies on thruster parameters (thrust, mass flow rate, specific impulse (Isp)), distance to receiver surface, and angle off plume centerline. For modeling purposes, contaminant mass released scales linearly with pulse width. This is a conservative approach for pulse widths greater than 80 ms but could under-predict contamination for very short pulse widths (i.e., with little or no steady state phase). This paper presents a model update to add a functional dependency on commanded pulse width to ensure the portion of the pulse spent in start-up and shut-down phases is appropriately modeled, when the majority of liquid phase contaminant mass is released. The updated model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations while providing a way to take advantage of thruster start-up and shut-down data gathered during test programs, if available. Developing the plume model for a specific thruster using the ISS Bipropellant Plume Contamination Model must be done in consideration of all available thruster performance data. Example thruster data will be used to illustrate this point and options for implementing the model update with existing ISS Bipropellant Plume Contamination Model code will be discussed.

plume contamination↗

NASA NTRS1995

Load measurement system with load cell lock-out mechanism

In the frame work of the project Shuttle Plume Impingement Flight Experiment (SPIFEX), a Load Measurement System was developed and fabricated to measure the impingement force of Shuttle Reaction Control System (RCS) jets. The Load Measurement System is a force sensing system that measures any combination of normal and shear forces up to 40 N (9 lbf) in the normal direction and 22 N (5 lbf) in the shear direction with an accuracy of +/- 0.04 N (+/- 0.01 lbf) Since high resolution is required for the force measurement, the Load Measurement System is built with highly sensitive load cells. To protect these fragile load cells in the non-operational mode from being damaged due to flight loads such as launch and landing loads of the Shuttle vehicle, a motor driven device known as the Load Cell Lock-Out Mechanism was built. This Lock-Out Mechanism isolates the load cells from flight loads and re-engages the load cells for the force measurement experiment once in space. With this highly effective protection system, the SPIFEX load measurement experiment was successfully conducted on STS-44 in September 1994 with all load cells operating properly and reading impingement forces as expected.

Le, Thang↗

NASA NTRS1993

Shuttle primary reaction control system engine exhaust plume contamination effects

Space Shuttle proximity operations constitute an important part of the SSF induced external environment. The impingement of primary reaction control system (PRCS) engine plumes on SSF functional surfaces during docking or berthing and separation leads to concerns about molecular contamination and high speed particle impact. The Shuttle Plume Impingement flight Experiment (SPIE) was designed to provide a direct measure of both the molecular contamination and particle impact rates produced by Shuttle PRCS engines in the LEO environment. The measured permanent deposition produced by PRCS engine firings was less than that assumed in current SSF programatic assessments. Only two to three possible high velocity particle impact pits were observed on the RMS end effector hardware.

Koontz, Steve↗

NASA NTRS1997

Comparison of Orbiter PRCS Plume Flow Fields Using CFD and Modified Source Flow Codes

The Space Shuttle Orbiter will use Reaction Control System (RCS) jets for docking with the planned International Space Station (ISS). During approach and backout maneuvers, plumes from these jets could cause high pressure, heating, and thermal loads on ISS components. The object of this paper is to present comparisons of RCS plume flow fields used to calculate these ISS environments. Because of the complexities of 3-D plumes with variable scarf-angle and multi-jet combinations, NASA/JSC developed a plume flow-field methodology for all of these Orbiter jets. The RCS Plume Model (RPM), which includes effects of scarfed nozzles and dual jets, was developed as a modified source-flow engineering tool to rapidly generate plume properties and impingement environments on ISS components. This paper presents flow-field properties from four PRCS jets: F3U low scarf-angle single jet, F3F high scarf-angle single jet, DTU zero scarf-angle dual jet, and F1F/F2F high scarf-angle dual jet. The RPM results compared well with plume flow fields using four CFD programs: General Aerodynamic Simulation Program (GASP), Cartesian (CART), Unified Solution Algorithm (USA), and Reacting and Multi-phase Program (RAMP). Good comparisons of predicted pressures are shown with STS 64 Shuttle Plume Impingement Flight Experiment (SPIFEX) data.

Rochelle, Wm. C.↗

NASA NTRS2001

Thermal Analysis for Orbiter and ISS Plume Impingement on International Space Station

The NASA Reaction Control System (RCS) Plume Model (RPM) is an exhaust plume flow field and impingement heating code that has been updated and applied to components of the International Space Station (ISS). The objective of this study was to use this code to determine if plume environments from either Orbiter PRCS jets or ISS reboost and Attitude Control System (ACS) jets cause thermal issues on ISS component surfaces. This impingement analysis becomes increasingly important as the ISS is being assembled with its first permanent crew scheduled to arrive by the end of fall 2000. By early summer 2001 , the ISS will have a number of major components installed such as the Unity (Node 1), Destiny (Lab Module), Zarya (Functional Cargo Block), and Zvezda (Service Module) along with the P6 solar arrays and radiators and the Z-1 truss. Plume heating to these components has been analyzed with the RPM code as well as additional components for missions beyond Flight 6A such as the Propulsion Module (PM), Mobile Servicing System, Space Station Remote Manipulator System, Node 2, and the Cupola. For the past several years NASA/JSC has been developing the methodology to predict plume heating on ISS components. The RPM code is a modified source flow code with capabilities for scarfed nozzles and intersecting plumes that was developed for the 44 Orbiter RCS jets. This code has been validated by comparison with Shuttle Plume Impingement Flight Experiment (SPIFEX) heat flux and pressure data and with CFD and Method of Characteristics solutions. Previous analyses of plume heating predictions to the ISS using RPM have been reported, but did not consider thermal analysis for the components nor jet-firing histories as the Orbiter approaches the ISS docking ports. The RPM code has since been modified to analyze surface temperatures with a lumped mass approach and also uses jet-firing histories to produce pulsed heating rates. In addition, RPM was modified to include plume heating from ISS jets to ISS components where the jet coordinates are specified, together with the engine cant angle. These latter studies have been focused on the PM with plumes from its reboost and ACS jets impinging on various ISS components and also focused on the Japanese H2 Transfer Vehicle (HTV) with the plumes from its reboost engines impinging on the Cupola window. This paper will present plume heating and surface temperature results on a number of ISS components with and without jet-firing histories, evaluate post-flight data, and describe any potential thermal issues

Rochelle, William C.↗

NASA NTRS2021

A Study into Validating a Coupled Method of Characteristics and Direct Simulation Monte Carlo Method Against Empirical Data

The following will outline the methodology and results of validating a coupled Method of Characteristics (MOC) and Direct Simulation Monte Carlo (DSMC) method. This research focused specifically on modeling plume impingement, induced by Reaction Control System (RCS) thrusters that flew on the National Aeronautics and Space Administration’s (NASA’s) space shuttle Discovery. For each simulation, the continuum portion of the RCS thruster was simulated using MOC for solving hyperbolic Partial Differential Equations (PDEs) and computed with the NASA code, Reacting and Multi-phase Program (RAMP). The solution was then implemented as a starting condition into the NASA DSMC code, Direct Simulation and Monte Carlo Analysis Code (DAC). Typically, DSMC models rely on code-to-code validation for fidelity. The significance of this research is in its ability to validate its models against empirical data. Prior to computing solutions for these simulations, the mesh size and structure were optimized and many variants of DSMC input parameters were iterated on in order to acquire a reliable, mesh-independent, fully optimized numerical solution. This research will discuss the mathematical formulation of MOC for nozzle flow and DSMC for rarefied gases. Additionally, it will provide an explanation of how to implement these mathematical concepts into the two solvers: RAMP and DAC. Ultimately, this research will demonstrate that the overall process illustrated produces results in good agreement with empirical data. As a consequence, the methodology presented is granted an increased level of confidence and will greatly contribute to the aerospace industry and its effort in understanding and predicting rarefied flow fields.

Direct Simulation Monte Carlo Analysis Code↗

NASA NTRS2024

The Effect of Impingement Angle on Bipropellant Thruster Plume Degradation of Spacecraft Materials

Unburned and partially combusted liquid propellant present in bipropellant thruster plumes can contaminate and damage external spacecraft materials. Microscopic impact features due to high-speed droplet impacts have been observed on space shuttle flight experiments and International Space Station (ISS) returned flight hardware. Analytical results have shown that particle impingement angle greatly affects surface damage, with normal impacts being the most severe and highly oblique impacts being more benign. The effect of thruster plume impingement angle on material degradation has now been further studied following a bipropellant thruster plume test performed at the high-vacuum plume test facility for chemical thrusters at DLR Göttingen, STG-CT. Several spacecraft material samples were exposed to the freely expanding pulsed thruster plume at a range of impingement angles (from 0 to 75 deg). Results of post-test evaluations and potential spaceflight applications are summarized.

Gateway↗

NASA NTRSDate not supplied

The Effect of Impingement Angle on Bipropellant Thruster Plume Degradation of Spacecraft Materials

Gateway↗

NASA NTRS2001

The Plume Impingement Contamination II Experiment: Motivation, Design, and Implementation Plan

The International Space Station (ISS) will have a long service life during which it must be able to serve as a capable platform for a wide variety of scientific investigations. In order to provide this capability, the ISS has, at the system level, a design requirement of no more than 100 Angstroms of contaminant deposition per year from "non-quiescent" sources. Non-quiescent sources include the plumes resulting from the firing of reaction control system (ReS) engines on space vehicles visiting the ISS as well as the engines on the ISS itself. Unfortunately, good general plume contamination models do not yet exist. This is due both to the complexity of the problem, making the analytic approach difficult, and to the difficulty in obtaining empirical measurements of contaminant depositions. To address this lack of flight data, NASA Johnson Space Center is planning to fly an experiment, Plume Impingement Contamination-II, to measure the contamination deposition from the Shuttle Orbiter's primary RCS engines as a function angle from plume centerline. This represents the first direct on-orbit measurement of plume impingement contamination away from the nozzle centerline ever performed, and as such is extremely important in validating mathematical models which will be used to quantify the cumulative plume impingement contamination to the ISS over its lifetime. The paper will elaborate further upon the motivation behind making these measurements as well as present the design and implementation plan of this planned experiment.

Lumpkin, Forrest E., III↗

NASA NTRS2026

Investigation of Bipropellant Plume-Induced Contamination Effects on Coverglass Materials

Contamination and degradation of external spacecraft materials by unburned and partially combusted species from bipropellant thruster plumes has long been observed as a key component of the induced space environment. Space shuttle flight experiments and returned flight hardware from the International Space Station (ISS) have both experienced microscopic impact features induced by high-velocity thruster plume droplets. Analytical results have shown that droplet impingement angle relative to a receiving surface plays a key role in the surface damage. Although impacts with normal impingement angles contribute more severely to surface degradation than highly oblique angles, surface effects at higher impingement angles should not be dismissed. Thruster plume-induced materials degradation is a complex phenomenon that depends on a variety of parameters, including but not limited to material type, system temperature and pressure, plume composition, and thruster firing specifications such as number of pulses, pulse duration, and sample distance from the thruster. For space applications, attaining the vacuum pressure and temperature conditions necessary for flight-like plume expansion and exposure conditions is not a trivial task. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt, DLR) is a facility uniquely capable of simulating such conditions. Test coupons were exposed to bipropellant thruster firings under high vacuum at the DLR facility. Percent area coverage (PAC) and droplet size distributions were evaluated for the uncoated and coated solar array coverglass materials over a range of impingement angles (0̊ to 75̊). A post-test imaging workflow was developed that aimed to quantify changes in sample surface morphology obtained from scanning electron microscopy (SEM) images using the Image Processing and Analysis in Java (ImageJ) tool; an opensource image processing software. The goal was to create a framework through which to evaluate the effect of bipropellant-induced PAC and droplet size distribution on solar array coverglass optical transmission losses. Understanding this relationship is important because optical transmission losses are known to lead to current reduction in solar power generation systems. In addition to the development of surface characterization workflows, valuable lessons learned as they pertain to future investigations and experiments will be discussed. The authors hope that sharing these lessons will facilitate more utilization of DLR’s unique capabilities as well as open the conversation for how best to address experimental characterization of flight-like plume expansion and its impacts on materials surface degradation effects.

Gateway↗

NASA NTRS1992

STS-52 Space Shuttle mission report

The STS-52 Space Shuttle Program Mission Report provides a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle main engine (SSME) subsystem performance during the fifty-first flight of the Space Shuttle Program, and the thirteenth flight of the Orbiter vehicle Columbia (OV-102). In addition to the Orbiter, the flight vehicle consisted of the following: an ET (designated as ET-55/LWT-48); three SSME's, which were serial numbers 2030, 2015, and 2034 in positions 1, 2, and 3, respectively; and two SRB's, which were designated BI-054. The lightweight RSRM's that were installed in each SRB were designated 360L027A for the left SRB and 360Q027B for the right SRB. The primary objectives of this flight were to successfully deploy the Laser Geodynamic Satellite (LAGEOS-2) and to perform operations of the United States Microgravity Payload-1 (USMP-1). The secondary objectives of this flight were to perform the operations of the Attitude Sensor Package (ASP), the Canadian Experiments-2 (CANEX-2), the Crystals by Vapor Transport Experiment (CVTE), the Heat Pipe Performance Experiment (HPP), the Commercial Materials Dispersion Apparatus Instrumentation Technology Associates Experiments (CMIX), the Physiological System Experiment (PSE), the Commercial Protein Crystal Growth (CPCG-Block 2), the Shuttle Plume Impingement Experiment (SPIE), and the Tank Pressure Control Experiment (TPCE) payloads.

Fricke, Robert W., Jr.↗

NASA NTRS1998

Use of microgravity sensors for quantification of space shuttle orbiter vernier reaction control system induced environments

In the modeling of spacecraft dynamics it is important to accurately characterize the environment in which the vehicle operates, including the environments induced by the vehicle itself. On the Space Shuttle these induced environmental factors include reaction control system plume. Knowledge of these environments is necessary for performance of control systems and loads analyses, estimation of disturbances due to thruster firings, and accurate state vector propagation. During the STS-71 mission, while the Orbiter was performing attitude control for the mated Orbiter/Mir stack, it was noted that the autopilot was limit cycling at a rate higher than expected from pre-flight simulations. Investigations during the mission resulted in the conjecture that an unmodelled plume impingement force was acting upon the orbiter elevons. The in-flight investigations were not successful in determining the actual magnitude of the impingement, resulting in several sequential post-flight investigations. Efforts performed to better quantify the vernier reaction control system induced plume impingement environment of the Space Shuttle orbiter are described in this paper, and background detailing circumstances which required the more detailed knowledge of the RCS self impingement forces, as well as a description of the resulting investigations and their results is presented. The investigations described in this paper applied microgravity acceleration data from two shuttle borne microgravity experiments, SAMS and OARE, to the solution of this particular problem. This solution, now used by shuttle analysts and mission planners, results in more accurate propellant consumption and attitude limit cycle estimates in preflight analyses, which are critical for pending International Space Station missions.

Friend, Robert B.↗

NASA NTRS1996

Test Outline for Flutter Analysis of Rectangular Panels in Rarefied Flow Conditions

Jet plume impingement forces acting on large flexible space structures may precipitate dynamically unstable behavior during space flights. Typical operating conditions in space involve rarefied gas flow regimes which are intrinsically distinct from continuum gas flow and are normally modeled using the kinetic theory of gas flow. Docking and undocking operations of the Space Shuttle with the Russian Mir space laboratory represent a scenario in which the stability boundaries of solar panels may be of interest. Extensive literature review of research work on the dynamic stability of rectangular panels in rarefied gas flow conditions indicated the lack of published reports dealing with this phenomenon. A recently completed preliminary study for NASA JSC dealing with the mathematical analysis of the stability of two-degree-of-freedom elastically supported rigid panels under the effect of rarefied gas flow was reviewed. A test plan outline is prepared for the purpose of conducting a series of experiments on four rectangular rigid test articles in a vacuum chamber under the effect of continuous and pulsating Nitrogen jet plumes. The purpose of the test plan is to gather enough data related to a number of key parameters to allow the validation of the two-degree-of-freedom mathematical model. The hardware required careful design to select a very lightweight material while satisfying rigidity and frequency requirements within the constraints of the test environment. The data to be obtained from the vacuum chamber tests can be compared with the predicted behavior of the theoretical two-degree-of-freedom model. Using the data obtained in this study, further research can identify the limitations of the mathematical model. In addition modifications to the mathematical model can be made, if warranted, to accurately predict the behavior of rigid panels under rarefied gas flow regimes.

Akl, Fred A.↗

NASA NTRS1983

Orbiter operations in close proximity to free-flying satellites or formation flying in space

The seventh orbital flight of the Space Shuttle had as one of its primary objectives the testing of the vehicle's capability for proximity operations (defined as anytime the Orbiter is within 1000 feet of another satellite). The goals of these tests were to obtain flight data on different techniques for separation from, stationkeeping with, and approach and capture of a free-flying satellite. This included the acquisition of data on technique evaluation as to propellant usage, time required, crew workload, plume disturbance to the payload by the reaction control system, and jet plume impingement. The tests were also to provide data on the rendezvous radar and optical sighting devices performance in this environment. It is concluded that the Orbiter proved to be a very responsive vehicle that ws straightforward to fly in the vicinity of another satellite given the proper experience base with ground simulations.

Crippen, R. L.↗