Extended temperature range rocket injector

A rocket injector is provided with multiple sets of manifolds for supplying propellants to injector elements. Sensors transmit the temperatures of the propellants to a suitable controller which is operably connnected to valves between these manifolds and propellant storage tanks. When cryogenic propellant temperatures are sensed, only a portion of the valves are opened to furnish propellants to some of the manifolds. When lower temperatures are sensed, additional valves are opened to furnish propellants to more of the manifolds

Auxiliary propulsion technology for advanced Earth-to-orbit vehicles

The payload which can be delivered to orbit by advanced Earth-to-Orbit vehicles is significantly increased by advanced subsystem technology. Any weight which can be saved by advanced subsystem design can be converted to payload at Main Engine Cut Off (MECO) given the same launch vehicle performance. The auxiliary propulsion subsystem and the impetus for the current hydrogen/oxygen technology program is examined. A review of the auxiliary propulsion requirements of advanced Earth-to-Orbit (ETO) vehicles and their proposed missions is given first. Then the performance benefits of hydrogen/oxygen auxiliary propulsion are illustrated using current shuttle data. The proposed auxiliary propulsion subsystem implementation includes liquid hydrogen/liquid oxygen (LH2/LO2) primary Reaction Control System (RCS) engines and gaseous hydrogen/gaseous oxygen (GH2/GO2) vernier RCS engines. A distribution system for the liquid cryogens to the engines is outlined. The possibility of providing one dual-phase engine that can operate on either liquid or gaseous propellants is being explored, as well as the simultaneous firing of redundant primary RCS thrusters to provide Orbital Maneuvering System (OMS) level impulse. Scavenging of propellants from integral main engine tankage is proposed to utilize main engine tank residuals and to combine launch vehicle and subsystem reserves

Low thrust chemical rocket technology

An on-going technology program to improve the performance of low thrust chemical rockets for spacecraft on-board propulsion applications is reviewed. Improved performance and lifetime is sought by the development of new predictive tools to understand the combustion and flow physics, introduction of high temperature materials and improved component designs to optimize performance, and use of higher performance propellants. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Predictions are based on both the RPLUS Navier-Stokes code with finite rate kinetics and the JANNAF methodology. Data were obtained with laser-based diagnostics along with global performance measurements. Results indicate that the modeling of the injector and the combustion process needs improvement in these codes and flow visualization with a technique such as 2-D laser induced fluorescence (LIF) would aid in resolving issues of flow symmetry and shear layer combustion processes. High temperature material fabrication processes are under development and small rockets are being designed, fabricated, and tested using these new materials. Rhenium coated with iridium for oxidation protection was produced by the Chemical Vapor Deposition (CVD) process and enabled an 800 K increase in rocket operating temperature. Performance gains with this material in rockets using Earth storable propellants (nitrogen tetroxide and monomethylhydrazine or hydrazine) were obtained through component redesign to eliminate fuel film cooling and its associated combustion inefficiency while managing head end thermal soakback. Material interdiffusion and oxidation characteristics indicated that the requisite lifetimes of tens of hours were available for thruster applications. Rockets were designed, fabricated, and tested with thrusts of 22, 62, 440 and 550 N. Performance improvements of 10 to 20 seconds specific impulse were demonstrated. Higher performance propellants were evaluated: Space storable propellants, including liquid oxygen (LOX) as the oxidizer with nitrogen hydrides or hydrocarbon as fuels. Specifically, a LOX/hydrazine engine was designed, fabricated, and shown to have a 95 pct theoretical c-star which translates into a projected vacuum specific impulse of 345 seconds at an area ratio of 204:1. Further performance improvment can be obtained by the use of LOX/hydrogen propellants, especially for manned spacecraft applications, and specific designs must be developed and advanced through flight qualification

Method of injecting fluid propellants into a rocket combustion chamber

A rocket injector is provided with multiple sets of manifolds for supplying propellants to injector elements. Sensors transmit the temperatures of the propellants to a suitable controller which is operably connected to valves between these manifolds and propellant storage tanks. Additional valves are opened to furnish propellants to more of the manifolds when cryogenic propellant temperatures are sensed. Only a portion of the valves are opened to furnish propellants to some of the manifolds when lower temperatures are sensed

High temperature thruster technology for spacecraft propulsion

A technology program intended to develop high-temperature oxidation-resistant thrusters for spacecraft applications is considered. The program will provide the requisite material characterizations and fabrication to incorporate iridium coated rhenium material into small rockets for spacecraft propulsion. This material increases the operating temperature of thrusters to 2200 C, a significant increase over the 1400 C of the silicide-coated niobium chambers currently used. Stationkeeping class 22 N engines fabricated from iridium-coated rhenium have demonstrated steady state specific impulses 20-25 seconds higher than niobium chambers. These improved performances are obtained by reducing or eliminating the fuel film cooling requirements in the combustion chamber while operating at the same overall mixture ratio as conventional engines

Weight savings in aerospace vehicles through propellant scavenging

Vehicle payload benefits of scavenging hydrogen and oxygen propellants are addressed. The approach used is to select a vehicle and a mission and then select a scavenging system for detailed weight analysis. The Shuttle 2 vehicle on a Space Station rendezvous mission was chosen for study. The propellant scavenging system scavenges liquid hydrogen and liquid oxygen from the launch propulsion tankage during orbital maneuvers and stores them in well insulated liquid accumulators for use in a cryogenic auxiliary propulsion system. The fraction of auxiliary propulsion propellant which may be scavenged for propulsive purposes is estimated to be 45.1 percent. The auxiliary propulsion subsystem dry mass, including the proposed scavenging system, an additional 20 percent for secondary structure, an additional 5 percent for electrical service, a 10 percent weight growth margin, and 15.4 percent propellant reserves and residuals is estimated to be 6331 kg. This study shows that the fraction of the on-orbit vehicle mass required by the auxiliary propulsion system of this Shuttle 2 vehicle using this technology is estimated to be 12.0 percent compared to 19.9 percent for a vehicle with an earth-storable bipropellant system. This results in a vehicle with the capability of delivering an additional 7820 kg to the Space Station

Advanced APS Impacts on Vehicle Payloads

Advanced auxiliary propulsion system (APS) technology has the potential to both, increase the payload capability of earth-to-orbit (ETO) vehicles by reducing APS propellant mass, and simplify ground operations and logistics by reducing the number of fluids on the vehicle and eliminating toxic, corrosive propellants. The impact of integrated cryogenic APS on vehicle payloads is addressed. In this system, launch propulsion system residuals are scavenged from integral launch propulsion tanks for use in the APS. Sufficient propellant is preloaded into the APS to return to earth with margin and noncomplete scavenging assumed. No propellant conditioning is required by the APS, but ambient heat soak is accommodated. High temperature rocket materials enable the use of the unconditioned hydrogen/oxygen in the APS and are estimated to give APS rockets specific impulse of up to about 444 sec. The payload benefits are quantified and compared with an uprated monomethyl hydrazine/nitrogen tetroxide system in a conservative fashion, by assuming a 25.5 percent weight growth for the hydrogen/oxygen system and a 0 percent weight growth for the uprated system. The combination and scavenging and high performance gives payload impacts which are highly mission specific. A payload benefit of 861 kg (1898 lbm) was estimated for a Space Station Freedom rendezvous mission and 2099 kg (4626 lbm) for a sortie mission, with payload impacts varying with the amount of launch propulsion residual propellants. Missions without liquid propellant scavenging were estimated to have payload penalties, however, operational benefits were still possible

Low thrust rocket test facility

A low thrust chemical rocket test facility has recently become operational at the NASA-Lewis. The new facility is used to conduct both long duration and performance tests at altitude over a thruster's operating envelope using hydrogen and oxygen gas for propellants. The facility provides experimental support for a broad range of objectives, including fundamental modeling of fluids and combustion phenomena, the evaluation of thruster components, and life testing of full rocket designs. The major mechanical and electrical systems are described along with aspects of the various optical diagnostics available in the test cell. The electrical and mechanical systems are designed for low down time between tests and low staffing requirements for test operations. Initial results are also presented which illustrate the various capabilities of the cell

Hydrogen/oxygen auxiliary propulsion technology

A survey is provided of hydrogen/oxygen (H/O) auxiliary propulsion system (APS) concepts and low thrust H/O rocket technology. A review of H/O APS studies performed for the Space Shuttle, Space Tug, Space Station Freedom, and Advanced Manned Launch System programs is given. The survey also includes a review of low thrust H/O rocket technology programs, covering liquid H/O and gaseous H/O thrusters, ranging from 6600 N (1500 lbf) to 440 mN (0.1 lbf) thrust. Ignition concepts for H/O thrusters and high temperature, oxidation resistant chamber materials are also reviewed