Propellant production and useful materials: Hardware data from components and the systems

During the past year significant progress included: a major breakthrough in oxygen production through discs (instead of tubes) that resulted in two orders-of-magnitude increase in the yield rates, proving that oxygen production from any iron-bearing silicate (avoiding costly beneficiation) in lunar in-situ resource utilization (ISRU); construction of a half-scale robotic soil processor; production of melt-spun fibers in a solar furnace; and the culmination of first-stage research in the construction (and delivery to NASA LaRC) of a self-contained portable oxygen plant that incorporates the first generation ISRU technologies developed at UA SERC. In addition, further reductions in mass and power needs were achieved in two smaller oxygen plants, which, however, have far greater production rates. SERC continued to attract bright students both at the undergraduate and graduate levels, and several area high school students through the Professional Internship Program (PIP) administered by the local school district. Invited lectures at elementary schools continue to draw enthusiastic response. Another important first was the creation of the Freshman Colloquium, 'Space in Our Future, and Our Future in Space,' geared toward women and minority students. This course proved to be a success, with more than one-half of the enrollment composed of women. In recognition of these important contributions, the author was appointed to the NRC Committee on Space Science Technologies

The University of Arizona program in solid propellants

The University of Arizona program is aimed at introducing scientific rigor to the predictability and quality assurance of composite solid propellants. Two separate approaches are followed: to use the modern analytical techniques to experimentally study carefully controlled propellant batches to discern trends in mixing, casting, and cure; and to examine a vast bank of data, that has fairly detailed information on the ingredients, processing, and rocket firing results. The experimental and analytical work is described briefly. The principle findings were that: (1) pre- (dry) blending of the coarse and fine ammonium perchlorate can significantly improve the uniformity of mixing; (2) the Fourier transformed IR spectra of the uncured and cured polymer have valuable data on the state of the fuel; (3) there are considerable non-uniformities in the propellant slurry composition near the solid surfaces (blades, walls) compared to the bulk slurry; and (4) in situ measurements of slurry viscosity continuously during mixing can give a good indication of the state of the slurry. Several important observations in the study of the data bank are discussed

Introduction to the problem

Solid propellant rockets were used extensively in space missions ranging from large boosters to orbit-raising upper stages. The smaller motors find exclusive use in various earth-based applications. The advantage of the solids include simplicity, readiness, volumetric efficiency, and storability. Important recent progress in related fields (combustion, rheology, micro-instrumentation/diagnostics, and chaos theory) can be applied to solid rockets to derive maximum advantage and avoid waste. Main objectives of research in solid propellants include: to identify critical parameters, to establish specification rules, and to develop quantitative criteria

Some Aspects of Pyrotechnic Modeling

Several aspects of pyrotechnic devices used to produce smoke, flash and sound are discussed quantitatively. The main aim of this paper is to demonstrate economical techniques to tailor pyrotechnic formulations to meet specific needs. It is seen that the cloud size is independent of the charge weight in the range of 2-80 gm, a theoretical result that is verified by experimental data. The noise is found to bein good agreement with experimental data, especially after allowance is made for absorption in the atmosphere. Several formulations are tested and the results are presented.Tailoring of pyrotechnics to achieve specific effects of cloud size, shape and longevity is discussed. Applications of pyrotechnics for gas generation purposes are also mentioned. It is seen that these studies complement more extensive testing; mutually, they introduce great economy and provide insight not possible with empirical approaches

NASA Space Engineering Research Center for Utilization of Local Planetary Resources

Progress toward the goal of exploiting extraterrestrial resources for space missions is documented. Some areas of research included are as follows: Propellant and propulsion optimization; Automation of propellant processing with quantitative simulation; Ore reduction through chlorination and free radical production; Characterization of lunar ilmenite and its simulants; Carbothermal reduction of ilmenite with special reference to microgravity chemical reactor design; Gaseous carbonyl extraction and purification of ferrous metals; Overall energy management; and Information management for space processing

Composite Solid Propellant Predictability and Quality Assurance

Reports are presented at the meeting at the University of Arizona on the study of predictable and reliable solid rocket motors. The following subject areas were covered: present state and trends in the research of solid propellants; the University of Arizona program in solid propellants, particularly in mixing (experimental and analytical results are presented)

Proof-of-concept automation of propellant processing

For space-based propellant production, automation of the process is needed. Currently, all phases of terrestrial production have some form of human interaction. A mixer was acquired to help perform the tasks of automation. A heating system to be used with the mixer was designed, built, and installed. Tests performed on the heating system verify design criteria. An IBM PS/2 personal computer was acquired for the future automation work. It is hoped that some the mixing process itself will be automated. This is a concept demonstration task; proving that propellant production can be automated reliably

Solid rocket combustion simulator technology using the hybrid rocket for simulation

The hybrid rocket is reexamined in light of several important unanswered questions regarding its performance. The well-known heat transfer limited burning rate equation is quoted, and its limitations are pointed out. Several inconsistencies in the burning rate determination through fuel depolymerization are explicitly discussed. The resolution appears to be through the postulate of (surface) oxidative degradation of the fuel. Experiments are initiated to study the fuel degradation in mixtures of nitrogen/oxygen in the 99.9 percent/0.1 percent to 98 percent/2 percent range. The overall hybrid combustion behavior is studied in a 2 in-diameter rocket motor, where a PMMA tube is used as the fuel. The results include detailed, real-time infrared video images of the combustion zone. Space- and time-averaged images give a broad indication of the temperature reached in the gases. A brief outline is shown of future work, which will specifically concentrate on the exploration of the role of the oxidizer transport to the fuel surface, and the role of the unburned fuel that is reported to escape below the classical time-averaged boundary layer flame

Development of a figure-of-merit for space missions

The concept of a quantitative figure-of-merit (FOM) to evaluate different and competing options for space missions is further developed. Over six hundred individual factors are considered. These range from mission orbital mechanics to in-situ resource utilization (ISRU/ISMU) plants. The program utilizes a commercial software package for synthesis and visual display; the details are completely developed in-house. Historical FOM's are derived for successful space missions such as the Surveyor, Voyager, Apollo, etc. A cost FOM is also mentioned. The bulk of this work is devoted to one specific example of Mars Sample Return (MSR). The program is flexible enough to accommodate a variety of evolving technologies. Initial results show that the FOM for sample return is a function of the mass returned to LEO, and that missions utilizing ISRU/ISMU are far more cost effective than those that rely on all earth-transported resources

NASA Space Engineering Research Center for Utilization of Local Planetary Resources

In the processing of propellants, volatiles, and metals subject area, the following topics are discussed: reduction of lunar regolith; reduction of carbon dioxide; and reduction of carbonaceous materials. Other areas addressed include: (1) production of structural and refractory materials; (2) resource discovery and characterization; (3) system automation and optimization; and (4) database development. The majority of these topics are discussed with respect to the development of lunar and mars bases. Some main topics of interest include: asteroid resources, lunar resources, mars resources, materials processing, construction materials, propellant production, oxygen production, and space-based oxygen production plants