One-Dimensional, Two-Phase Flow Modeling Toward Interpreting Motor Slag Expulsion Phenomena

Aluminum oxide slag accumulation and expulsion was previously shown to be a player in various solid rocket motor phenomena, including the Space Shuttle's Reusable Solid Rocket Motor (RSRM) pressure perturbation, or "blip," and phantom moment. In the latter case, such un ]commanded side accelerations near the end of burn have also been identified in several other motor systems. However, efforts to estimate the mass expelled during a given event have come up short. Either bulk calculations are performed without enough physics present, or multiphase, multidimensional Computational Fluid Dynamic analyses are performed that give a snapshot in time and space but do not always aid in grasping the general principle. One ]dimensional, two ]phase compressible flow calculations yield an analytical result for nozzle flow under certain assumptions. This can be carried further to relate the bulk motor parameters of pressure, thrust, and mass flow rate under the different exhaust conditions driven by the addition of condensed phase mass flow. An unknown parameter is correlated to airflow testing with water injection where mass flow rates and pressure are known. Comparison is also made to full ]scale static test motor data where thrust and pressure changes are known and similar behavior is shown. The end goal is to be able to include the accumulation and flow of slag in internal ballistics predictions. This will allow better prediction of the tailoff when much slag is ejected and of mass retained versus time, believed to be a contributor to the widely-observed "flight knockdown" parameter

A One-Dimensional Global-Scaling Erosive Burning Model Informed by Blowing Wall Turbulence

A derivation of turbulent flow parameters, combined with data from erosive burning test motors and blowing wall tests results in erosive burning model candidates useful in one-dimensional internal ballistics analysis capable of scaling across wide ranges of motor size. The real-time burn rate data comes from three test campaigns of subscale segmented solid rocket motors tested at two facilities. The flow theory admits the important effect of the blowing wall on the turbulent friction coefficient by using blowing wall data to determine the blowing wall friction coefficient. The erosive burning behavior of full-scale motors is now predicted more closely than with other recent models

A One-Dimensional Global-Scaling Erosive Burning Model Informed by Blowing Wall Turbulence

This paper makes no attempt to comprehensively review erosive burning models or the data collected in pursuit of them; the interested reader could begin with Landsbaum for a historical summary. However, a discussion and comparison to recent work by McDonald and Rettenmaier and Heister will be included, along with data generated by Strand, et. al. Suffice it to say that the search for a way to predict erosive burning in any size motor with formulas cleanly applicable to a typical 1D ballistics analysis has been long thwarted. Some models were based on testing that failed to adequately simulate the solid rocket motor environment. In most cases, no realtime burn rate measurement was available. Two popular models, even when calibrated to recent motorlike realtime burn rate data obtained by Furfaro, were shown by McMillin to be inadequate at modeling erosive burning in the Space Shuttle Reusable Solid Rocket Motor (RSRM), the Space Launch Systems' FiveSegment RSRM (RSRMV), and the fivesegment Engineering Test Motor (ETM)3. Subsequently to the data cited from Strand and Furfaro, additional motors of the same kind as Furfaro's were tested with RSRMV propellant, utilizing 7 segments per motor and 3 throat sizes. By measuring propellant web thickness with ultrasonic gages, the burn rate was determined at crossflow Mach numbers up to Mach 0.8. Furthermore, because of the different throat sizes in otherwise identical motors, this provides a unique look at the effect of pressure and base burn rate on the erosive response. Figure 1 shows example of the data pertaining to the high Mach motor, where the port area is initially less than the throat area. The burn rate data was processed using a smoothing method developed to reduce the noise without too severely introducing end effects that limit the range of useful data. Then, an empirical ballistics scheme was used to estimate the flow condition based on the burn rate measurements and pressure measured between each segment

A Design for a Two-Stage Solid Mars Ascent Vehicle

A solid propulsion system design is being considered for a conceptual Mars Ascent Vehicle (MAV) as part of a potential robotic Mars Sample Return campaign. A Preliminary Architecture Assessment for a MAV is being conducted at Marshall Space Flight Center. Experts from all relevant areas are involved in a rapid design and analysis cycle to define a MAV vehicle utilizing solid propulsion. The design presented here is the solid motor propulsion concept result of the study. Whereas solid motors have been used on Mars missions in the past during descent, none have been required to reside on the surface for a period of time prior to functioning. This difference will expose the MAV to relatively extreme temperatures. Other challenges exist in designing a solid propulsion system for MAV including performance interactions with other vehicle inert masses and minimizing orbit dispersions. These considerations were examined and a preliminary CAD model of the motors was created. Along with additional pertinent inputs from other disciplines, a solid propulsion vehicle concept for the MAV is described

A Design for a Two-Stage Solid Mars Ascent Vehicle

No abstract availabl

Characterization and Detailed Analysis of Regression Behavior for HTPB Solid Fuels Containing High Aluminum Loadings

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. For (especially) metalized fuels, hybrid references have pointed out possible dependence of fuel regression rate on a number of variables: mass flux, G - oxidizer only (G0), or - total mass flux (Gtot), Length, L, Pressure, P, and Diameter, D

Characterization, Operation and Analysis of Test Motors Containing Aluminized Hybrid Fuels

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. Testing for fuel regression rate comprised a two-level, full factorial design available over Aluminum loading level, mass flow rate, pressure, and diameter. The data taken significantly surpasses the previous available data on regression rate of aluminized HTPB fuel burning with gaseous oxygen. It encompasses higher mass fluxes, and appears to generate more consistent data. The good test article and facility design and testing work of the Penn State HPCL combined with careful analysis of the data and good planning has made this possible. This should be able to assist with developing rate laws that are useful both for research planning and for developing flight system sizing relationships that can help optimize hybrid rocket concepts for trade studies. The successful approach of this DOE and test setup is applicable to other propellant combinations as well

Enabling Dedicated, Affordable Space Access Through Aggressive Technology Maturation

A launch vehicle at the scale and price point which allows developers to take reasonable risks with high payoff propulsion and avionics hardware solutions does not exist today. Establishing this service provides a ride through the proverbial technology "valley of death" that lies between demonstration in laboratory and flight environments. NASA's NanoLaunch effort will provide the framework to mature both earth-to-orbit and on-orbit propulsion and avionics technologies while also providing affordable, dedicated access to low earth orbit for cubesat class payloads

Mars Ascent Vehicle (MAV) Solid Motor Technology Plans

Recent trades have taken place on solid propulsion options to support a potential Mars Sample Retrieval Campaign. Mass and dimensional requirements for a Mars Ascent Vehicle (MAV) are being assessed. One MAV vehicle concept would utilize a solid propulsion system. Key challenges to designing a solid propulsion system for MAV include low temperatures beyond common tactical and space requirements, performance, planetary protection, mass limits, and thrust vector control system. Two solutions are addressed, a modified commercial commercially available system, and an optimum new concept

Mars Ascent Vehicle Propulsion System Solid Motor Technology Plans

Mars Ascent Vehicle Study Summary: Potential Mars Sample Return Campaign; Assumptions; Motor Sizing; Propellant Selection; Nozzle and Controls; Development and Qualification Testing; Future Work