Summary of LOX/CH4 Thruster Technology Development at NASA/MSFC

In recent years, a variety of injectors for liquid oxygen (LOX) and methane (CH4) propellant systems have been designed, fabricated, and demonstrated with hot-fire testing at Marshall Space Flight Center (MSFC). Successful designs for liquid methane (LCH4) and gaseous methane (GCH4) have been developed. A variety of chambers, including a transpiration cooled design, along with uncooled ablatives and refractory metals, have also been hot-fire tested by MSFC for use with LOX/LCH4 injectors. Hot-fire testing has also demonstrated multiple ignition source options. Heat flux data for selected injectors has been gathered by testing with a calorimeter chamber. High performance and stable combustion have been demonstrated, along with designs for thrust levels ranging from 500 to 7,000 lbf. The newest LOX/CH4 injector and chamber developed by MSFC have been fabricated with additive manufacturing techniques and include unique design features to investigate regenerative cooling with methane. This low cost and versatile hardware offers a design for 4,000 lbf thrust and will be hot-fire tested at MSFC in 2015. Its design and operation can easily be scaled for use in systems with thrust levels up to 25,000 lbf

Design verification test matrix development for the STME thrust chamber assembly

This report presents the results of the test matrix development for design verification at the component level for the National Launch System (NLS) space transportation main engine (STME) thrust chamber assembly (TCA) components including the following: injector, combustion chamber, and nozzle. A systematic approach was used in the development of the minimum recommended TCA matrix resulting in a minimum number of hardware units and a minimum number of hot fire tests

Swirl Coaxial Injector Testing with LOX/RP-J

Testing was conducted at NASA fs Marshall Space Flight Center (MSFC) in the fall of 2012 to evaluate the operation and performance of liquid oxygen (LOX) and kerosene (RP ]1) in an existing swirl coaxial injector. While selected Russian engines use variations of swirl coaxial injectors, component level performance data has not been readily available, and all previously documented component testing at MSFC with LOX/RP ]1 had been performed using a variety of impinging injector designs. Impinging injectors have been adequate for specific LOX/RP ]1 engine applications, yet swirl coaxial injectors offer easier fabrication efforts, providing cost and schedule savings for hardware development. Swirl coaxial elements also offer more flexibility for design changes. Furthermore, testing with LOX and liquid methane propellants at MSFC showed that a swirl coaxial injector offered improved performance compared to an impinging injector. So, technical interest was generated to see if similar performance gains could be achieved with LOX/RP ]1 using a swirl coaxial injector. Results would allow such injectors to be considered for future engine concepts that require LOX/RP ]1 propellants. Existing injector and chamber hardware was used in the test assemblies. The injector had been tested in previous programs at MSFC using LOX/methane and LOX/hydrogen propellants. Minor modifications were made to the injector to accommodate the required LOX/RP ]1 flows. Mainstage tests were performed over a range of chamber pressures and mixture ratios. Additional testing included detonated gbombs h for stability data. Test results suggested characteristic velocity, C*, efficiencies for the injector were 95 ]97%. The injector also appeared dynamically stable with quick recovery from the pressure perturbations generated in the bomb tests

Paper Session I-A - Robust Low Cost Liquid Rocket Combustion Chamber By Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines require materials that can meet high temperatures while resisting the corrosive oxidation-reduction reaction of combustion known as blanching, the main cause of engine failure. A project was initiated at NASA-Marshall Space Flight Center (MSFC) to combine three existing technologies to build and demonstrate an advanced liquid rocket engine combustion chamber that would provide a 100-mission life. Technology developed in microgravity research to build cartridges for space furnaces was utilized to vacuum plasma spray (VPS) a functional gradient coating on the hot wall of the combustion liner as one continuous operation, eliminating any bondline between the coating and the liner. (See Figure 1) The coating was NiCrAlY, developed previously as durable protective coatings on space shuttle high-pressure fuel turbopump (HPFTP) turbine blades. A thermal model showed that 0.035” NiCrAlY applied to the hot wall of the combustion liner would reduce the hot wall temperature 200°F, a 20% reduction, for longer life. Cu-8Cr-4Nb alloy, which was developed by NASA-Glenn Research Center (GRC), and which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability, was utilized as the liner material in place of NARloy-Z. The Cu-8Cr-4Nb material exhibits better mechanical properties at 650°C (1200°F) than NARloy-Z does at 538°C (1000°F). VPS formed Cu-8Cr-4Nb combustion chamber liners with a protective NiCrAlY functional gradient coating have been hot fire tested, successfully demonstrating a durable coating for the first time. Hot fire tests along with tensile and low cycle fatigue properties of the VPS formed combustion chamber liners and witness panel specimens are discussed

Lightweight, Actively Cooled Ceramic Matrix Composite Thrustcells Successfully Tested in Rocket Combustion Lab

In a joint effort between the NASA Glenn Research Center and the NASA Marshall Space Flight Center, regeneratively cooled ceramic matrix composite (CMC) thrustcells were developed and successfully tested in Glenn's Rocket Combustion Lab. Cooled CMC's offer the potential for substantial weight savings over more traditional metallic parts. Two CMC concepts were investigated. In the first of these concepts, an innovative processing approach utilized by Hyper-Therm, Inc., allowed woven CMC coolant containment tubes to be incorporated into the complex thruster design. In this unique design, the coolant passages had varying cross-sectional shapes but maintained a constant cross-sectional area along the length of the thruster. These thrusters were silicon carbide matrix composites reinforced with silicon carbide fibers. The second concept, which was supplied by Ceramic Composites, Inc., utilized copper cooling coils surrounding a carbon-fiber-reinforced carbon matrix composite. In this design, a protective gradient coating was applied to the inner thruster wall. Ceramic Composites, Inc.'s, method of incorporating the coating into the fiber and matrix eliminated the spallation problem often observed with thermal barrier coatings during hotfire testing. The focus of the testing effort was on screening the CMC material's capabilities as well as evaluating the performance of the thermal barrier or fiber-matrix interfacial coatings. Both concepts were hot-fire tested in gaseous O2/H2 environments. The test matrix included oxygen-to-fuel ratios ranging from 1.5 to 7 with chamber pressures to 400 psi. Steady-state internal wall temperatures in excess of 4300 F were measured in situ for successful 30-sec test runs. Photograph of actively cooled composite thrustcell fabricated by Hyper-Therm is shown. The thrustcell is a silicon-carbide-fiber-reinforced silicon carbide matrix composite with woven cooling channels. The matrix is formed via chemical vapor infiltration. Photograph of hot-fire test of an actively cooled carbon-fiber-reinforced carbon matrix composite thrustcell is also shown. This composite thrustcell, which was fabricated by CCI, Inc., was wound with copper cooling coils to contain the water coolant. The tests were run with oxygen fuel ratios up to seven with chamber pressures of 200 psia

Fabrication and Testing of Low Cost 2D Carbon-Carbon Nozzle Extensions at NASA/MSFC

Subscale liquid engine tests were conducted at NASA/MSFC using a 1.2 Klbf engine with liquid oxygen (LOX) and gaseous hydrogen. Testing was performed for main-stage durations ranging from 10 to 160 seconds at a chamber pressure of 550 psia and a mixture ratio of 5.7. Operating the engine in this manner demonstrated a new and affordable test capability for evaluating subscale nozzles by exposing them to long duration tests. A series of 2D C-C nozzle extensions were manufactured, oxidation protection applied and then tested on a liquid engine test facility at NASA/MSFC. The C-C nozzle extensions had oxidation protection applied using three very distinct methods with a wide range of costs and process times: SiC via Polymer Impregnation & Pyrolysis (PIP), Air Plasma Spray (APS) and Melt Infiltration. The tested extensions were about 6" long with an exit plane ID of about 6.6". The test results, material properties and performance of the 2D C-C extensions and attachment features will be discussed

Rapid Vacuum Plasma Spray (VPS) Closeout of Liquid Rocket Engine Combustion Chamber Cooling Channels for Both Time and Cost Savings

This viewgraph presentation describes the Rapid Vacuum Plasma Spray (VPS) and its rapid closeout of combustion chamber cooling channels for reduced time and reduced costs

Survey of Constellation-Era LOX/Methane Development Activities and Future Development Needs

NASA formed the Constellation Program in 2005 to achieve the objectives of maintaining American presence in low-Earth orbit, returning to the moon for purposes of establishing an outpost, and laying the foundation to explore Mars and beyond in the first half of the 21st century. The Exploration Technology Development Program (ETDP) was formulated to address the technology needs to address Constellation architecture decisions. The Propellants and Cryogenic Advanced Development (PCAD) project was tasked with risk mitigation of specific propulsion related technologies to support ETDP. Propulsion systems were identified as critical technologies owing to the high gear-ratio of lunar Mars landers Cryogenic propellants offer performance advantage over storables (NTOMMH) Mass savings translate to greater payload capacity In-situ production of propellant an attractive feature; methane and oxygen identified as possible Martian in-situ propellants New technologies were required to meet more difficult missions High performance LOX/LH2 deep throttle descent engines High performance LOX/LCH4 ascent main and reaction control system (RCS) engines The PCAD project sought to provide those technologies through Reliable ignition pulse RCS Fast start High efficiency engines Stable deep throttling

The Human Connectome Project: A retrospective

The Human Connectome Project (HCP) was launched in 2010 as an ambitious effort to accelerate advances in human neuroimaging, particularly for measures of brain connectivity; apply these advances to study a large number of healthy young adults; and freely share the data and tools with the scientific community. NIH awarded grants to two consortia; this retrospective focuses on the WU-Minn-Ox HCP consortium centered at Washington University, the University of Minnesota, and University of Oxford. In just over 6 years, the WU-Minn-Ox consortium succeeded in its core objectives by: 1) improving MR scanner hardware, pulse sequence design, and image reconstruction methods, 2) acquiring and analyzing multimodal MRI and MEG data of unprecedented quality together with behavioral measures from more than 1100 HCP participants, and 3) freely sharing the data (via the ConnectomeDB database) and associated analysis and visualization tools. To date, more than 27 Petabytes of data have been shared, and 1538 papers acknowledging HCP data use have been published. The HCP-style neuroimaging paradigm has emerged as a set of best-practice strategies for optimizing data acquisition and analysis. This article reviews the history of the HCP, including comments on key events and decisions associated with major project components. We discuss several scientific advances using HCP data, including improved cortical parcellations, analyses of connectivity based on functional and diffusion MRI, and analyses of brain-behavior relationships. We also touch upon our efforts to develop and share a variety of associated data processing and analysis tools along with detailed documentation, tutorials, and an educational course to train the next generation of neuroimagers. We conclude with a look forward at opportunities and challenges facing the human neuroimaging field from the perspective of the HCP consortium

The Human Connectome Project: A retrospective

The Human Connectome Project (HCP) was launched in 2010 as an ambitious effort to accelerate advances in human neuroimaging, particularly for measures of brain connectivity; apply these advances to study a large number of healthy young adults; and freely share the data and tools with the scientific community. NIH awarded grants to two consortia; this retrospective focuses on the “WU-Minn-Ox” HCP consortium centered at Washington University, the University of Minnesota, and University of Oxford. In just over 6 years, the WU-Minn-Ox consortium succeeded in its core objectives by: 1) improving MR scanner hardware, pulse sequence design, and image reconstruction methods, 2) acquiring and analyzing multimodal MRI and MEG data of unprecedented quality together with behavioral measures from more than 1100 HCP participants, and 3) freely sharing the data (via the ConnectomeDB database) and associated analysis and visualization tools. To date, more than 27 Petabytes of data have been shared, and 1538 papers acknowledging HCP data use have been published. The “HCP-style” neuroimaging paradigm has emerged as a set of best-practice strategies for optimizing data acquisition and analysis. This article reviews the history of the HCP, including comments on key events and decisions associated with major project components. We discuss several scientific advances using HCP data, including improved cortical parcellations, analyses of connectivity based on functional and diffusion MRI, and analyses of brain-behavior relationships. We also touch upon our efforts to develop and share a variety of associated data processing and analysis tools along with detailed documentation, tutorials, and an educational course to train the next generation of neuroimagers. We conclude with a look forward at opportunities and challenges facing the human neuroimaging field from the perspective of the HCP consortium