NASA supports a vigorous Earth-to-orbit (ETO) research and technology program as part of its Civil Space Technology Initiative. The purpose of this program is to provide an up-to-date technology base to support future space transportation needs for a new generation of lower cost, operationally efficient, long-lived and highly reliable ETO propulsion systems by enhancing the knowledge, understanding and design methodology applicable to advanced oxygen/hydrogen and oxygen/hydrocarbon ETO propulsion systems. Program areas of interest include analytical models, advanced component technology, instrumentation, and validation/verification testing. Organizationally, the program is divided between technology acquisition and technology verification as follows: (1) technology acquisition; and (2) technology verification

Gentz, Steven J.

English

NASA Technical Reports Server

N93-22990
5.0 ADVANCED PROPULSION
5.1 CSTI Earth-to-Orbit
Propulsion R&T Program
Overview - Steven J. Gentz,
Marshall Space Flight Center
NASA supports a vigorous Earth-to-orbit
(ETO) research and technology program as
part of its Civil Space Technology Initiative.
The purpose of this program is to provide an
up-to-date technology base to support future
space transportation needs for a new
generation of lower cost, operationally-
efficient, long-lived and highly reliable
ETO propulsion systems by enhancing the
knowledge, understanding and design
methodology applicable to advanced
oxygen/hydrogen and oxygen/hydrocarbon
ETO propulsion systems. Program areas of
interest include analytical models,
advanced component technology,
instrumentation, and validation/veri-
fication testing. Organizationally, the
program is divided between technology
acquisition and technology verification as
follows:
• Technology Acquisition
- Bearings
- Structural Dynamics
- Turbomachinery
- Fatigue, Fracture and Life
- Ignition and Combustion
- Fluid and Gas Dynamics
- Instrumentation
- Controls
- Manufacturing, Producibility and
Inspection
- Materials
• Technology Verification
- Large Scale Combustors
- Large Scale Turbomachinery
- Controls and Health Monitoring
The ETO Propulsion Technology Program
is tightly linked to the user community, and
it supports all advanced engine programs.
Many of these program elements are
directly related to advanced materials and
structures, as are recent program highlights
such as the demonstration of extended life
silicon nitride bearings.
NASA's ETO Program is well-coordinated
with research and development activities by
industry and other government agencies to
avoid duplication of effort. NASA's efforts
in the area of aerospike engines are limited
to a small study effort because SDIO is
sponsoring significant research as part of
its SSTO program. Similarly, the ETO
program is monitoring the airbreathing
propulsion work in progress by NASP
rather than fund a separate effort.
PREIg_EDING P_pE BLANK NOT FtLM_
119
https://ntrs.nasa.gov/search.jsp?R=19930012901 2020-03-17T06:26:14+00:00Z
i=
NASA CSTI
Earth-To-Orbit
Propulsion R& T Program
Overview
James L. Moses
MSFC
Presenled
by
Sieve J. Gentz, MSFC
121
PRE_OING P.eIGE E_LANK NOT Fft-MF.D
NASA Earth-To-Orbit Propulsion R& T Program
Pur_ump_ 
• Provide an up-to-date technology base to support future space transportation
needs
Ob!ective
• Continuing enhancement of knowledge, understanding, and
methodology applicable to the development of advanced oxygen/hydrogen
and oxygen/hydrocarbon ETO propulsion systems
Justification
• Space transportation systems can benefit from advancements in propulsion
system performance, service life and automated operations and diagnostics
Contents
• Analytical models for defining engine environments and for predicting
hardware life (flow codes, loads definition, material behavior, structural
response, fracture mechanics, combustion performance and stability, heat
transfer)
• Advanced component technoIoav (bearings, seals, turbine blades, active
dampers, materials, processes.coatings, advanced manufacturing)
Instrumentation for empirically defining engine environments, for
performance analysis, and for health monitoring ( flow meters, pressure
transducers, bearing wear detectors, optical temperature sensors)
• _eerina testina at subcomponent level to validate analytical models,
verify advanced materials, and to verify advanced sensor life and
performance
• Component/test bed engine for validation/verification testing in true operating
environments
122
NASA Earth-to-Orbit Propulsion R& T Program
Work Breakdown
• Technology acquisition phase
- Seeks improved understanding of the basic chemical and physical
processes of propulsion
- Develops analyses, design models and codes using analytical
techniques supported by empirical laboratory data as required
- Results are obtained through ten discipline working groups
• Bearings
• Structural dynamics
• Turbomachinery
• Fatigue/fracture/life
• Ignition/combustion
• Fluid & gas dynamics
• Instrumentation
• Controls
• Manufacturing/producibility/inspection
• Materials
Work Breakdown (Continued)
• Technology verification phase
- Validates technology arising from the acquisition phase at the
large scale component, subsystem or engine system (l-rB) level
- Three categories of effort
• Large scale combustors
• Large scale turbomachinery
• Controls and health monitoring
123
Transportation Technology
Earth-To-Orbit Transportation
Earth-to-Orbit Propulsion ]
OBJECTIVES
• Programmatic
Develop and validate technology, design tools and methodologies
needed for the development of a new generation of lower cost,
operationally-efficient, long-life, highly reliable ETO propulsion
_,CHEDULE
• 1992 Electronic engine simulation capability operational
• 1993 3D CFD cedes for turbomachinery flows validated and
documented
• 1995 Low cost manufacturing processes applicable to shuttle
and NLSIHLLV propulsion verified and documented
systems
Technical
Manufacturing
Safely
Maintainability
Ground Ops
Performance
Advanced Cycles
High quality, low cost, Inspectable
Safe shutdown to fault tolerant ops
Condition monitoring diagnostics
Automated servicing and checkout
Max commensurate with life
Full flow, combined cycle, et¢,
RESOURCES* CU..E,,T
• 1991 $21.8 M
• 1992 $28.7 M
* 1993 $33.9 M
• 1994 $25.1 M
* 1995 $26.4 M
• 1996 $27.6 M
• 1997 $28.8 M
• Note: This element is closely coordinated with development
efforts in NASNOSF and other related government
programs; resources shown are NASNOAET only
• 1996
• 1999
,2005
System moniloriog capability for safe shutdown and for
enhanced preflight servicing and checkout demonstrated
Probabillstic codes, fatigue methodology and life
prediction/damage models validated and documented
Advanced manufacturing processes and design
methodologies applicable to fully reusable, long-life AMLS
propulsion verified and documented; propulsion system
monitoring and control for automated operations
demonstrated
PARTICIPANTS
• Marshall Space Flight Center
Lead Center-technology acquisition, test rig validation, large scale
validation, technology test bed
• Lewis Research Center
Participating Center-technology acquisition, test rig validation
• Langley Research Center
Supporting Center-vehicle systems analysis
• Stennls Space Center
Supporting Center4acility turbomachlnery
ETO Propulsion Technology Approach
• Civil Space Technology Initiative (CSTI) program emphasizes validated technology
delivered on schedule.
• Concepts, codes, techniques obtained in the Technology Acquisition Phase.
• Validated at the appropriate level by means of component subsystem or system
level testing (I-I'B).
• OAET provides technology to "I-I'B. OSF provides integration funds to incorporate
technology items into TTB.
• Technology is transferred to industry via papers & conferences such as Biannual
Propulsion Conference at MSFC and Biannual Structural Dynamics Conference at
LeRC.
- Technologists also are working flight programs
• Technology must be generic, but should be applicable to on-going or anticipated
programs.
- Goal is to provide a broad technology base that will support a wide variety of
propulsion options
124
ETO PROPULSION FUNDING SUMMARY - $K
I _¥89 I F¥901 F¥9_[ _¥821 _93 [ _94] F¥95I _¥96
TECHNOLOGY ACQUISITION
BEARINGS
STRUC. DYNAMICS
TURBOMACHINERY
FATIGUE/FRACTURE
CC_SllON
FLUID & GAS DYN.
INSTRUMENTATION
OONTROLS
MANUFACTURING
MATERIALS
TOTAL TECH. ACO.
VALIDATION
COMBUSTION VAUD.
TURBO. VALID.
SYS. MONITOR. VAUD.
TOTAL VAL/DAT/ON
TOTAL PROGRAM
PMS
CENTER TOTALS
2093 1561 1562 1200 1200 800 1000 1200
1371 1162 1350 1400 1800 1500 1700 1700
1229 1137 1764 1600 1600 1100 1050 1200
1285 837 1115 1200 1410 1200 1200 1200
3123 2875 1126 1700 1960 1200 1000 1200
1600 989 1697 1300 1200 900 1000 1200
1420 836 920 1100 1400 1000 1000 1200
1753 1182 1455 1800 1600 1000 1050 1200
763 835 1086 1100 1650 1300 1300 1400
1580 1020 1270 1000 1400 600 1000 1200
16217 12434 13347 13400 15220 10800 11300 12700
2160 622 750 1100 1780 1100 1200 2000
5285 2412 4619 3000 4700 3600 3600 3600
4578 4459 2606 6000 8800 6000 6500 5300
12023 7493 7975 12100 15280 10700 11300 10900
28240 19927 21322 25500 30500 21500 22600 23600
3375 3484 2616 3200 3400 3600 3800 4000
31615 23411 23938 28700 33900 25100 26400 27600
FY91
ETO FUNDING DISTRIBUTION
MSFC & LeRC
IN-HOUSE
25.5 %
UNIVERSITIES
16.9%
GOVERNMENT
12.7 %
PRIME
CONTRACTORS
12.7 %
OTHER
CONTRACTORS
32.2 %
125
ETOPROPULSIONTECHNOLOGY
EMPHASIS
MSFC& LeRC
PY91
COMMON
LOW COST
PERFORMANCE
INTEGRATED TECHNOLOGY PLAN FOR THE CIVIL SPACE PROGRAM
FLIGHT PROGRAMS VISION
OFFICE OF SPACE FLIGHT
_/----_ ' IASSURED SHUT-rLE AVAILABILrl"Y PROGRAM
1 'SPACE SHUTTLE EVOLUTIONI
PERSONNEL LAUNCH SYSTEM (PLS)
I
4/" AMLSISTS-FOLLOW ON
SPACE STATION FREEDOM
EXPENDABLE LAUNCH VEHICLES (ELV't)
HEAVY LIFT LAUNCH VEHICLE
1
CARGO TRANSFER VEHICLE (CTV}
1
" SP. XFER VEHICLE (STV)
1995 2000 20t0 2020
126
NASA Earth-To-Orbit Propulsion R&T Program
Recent Program Hio,_hli.gb_
• Silicon nitride bearings have shown greatly extended life over SSME flight bearings in MSFC
bearing tester.
• Completed assembly of a cryogenic rolling element bearing tester at LeRC.
• Turbopump test stand design complete. Stand is in MSFC FY93 C of F budget.
- Reviewed with Headquarters August 1990
• First ever measurement of heat flux on a flight type rocket engine turbine blade with a plug type
heat flux sensor.
• Management approval obtained for proceeding with advanced main combustion chamber
technology (full scale program).
- Reviewed with Headquarters April 1990
- Concept adopted by STME and evolutionary SSME
• CFD Consortium turbine team is interactive with ALS Design Process
Earth- To-Orbit Propulsion R& T Program Activities
• Conducted biannual ETO Technology Conference May 15-17, 1990. 123
papers presented. 400 attendees.
• Conducted Propulsion Program Review for OAET, September 16-18,1991.
• Conducted Detailed ALS assessment of ETO Propulsion Project,
March 1991, MSFC.
• Conducted 3rd screening of technology items for TTB March 8, 1991.
• Conducted biannual Structural Durability Conference at LeRC, May 1991.
• Presented program to Space Systems and Technology Advisory Committee,
June 1991.
• Presented program to Space Technology Interdependency Group (STIG)
July 12, 1991, JSC.
127
Focused Technology: ETO Propulsion
Summary
IP_M_P_A_r:The ETO Propulsion Technology Program supports all advanced engine programs. Half of the
200 tasks in the Program were judged by an ALS consortium contractor team to be directly applicable to
ALS propulsion technology needs. ETO addresses the top 3 priority technology issues of the Office of
Manned Space Flight,
_USER COORDINATION: Closely tied to SSME/ALS. SSME review held at Tyson's Comer, Va., Oct.1989.
ALS/SSME review held at MSFC February 1990. A special ALS review was held for ALS at MSFC in March
1991. Interagency coordination provided by Space Technology Interdependency Group (STIG).
TECHNICAL REVIEWS: Annual RTOP review held in Nov/Dec each year, Government only. Covers each
task, technical and budget, in the program. Other reviews as required.
OVERALL TECHNICAL and PROGRAMMATIC STATUS: Activities are maturing. Technology items for
validation are being developed, such as bearings, sensors, and health monitoring algorithms.
.ELAILQNALE for AUGMENTATION: Several areas require additional funding, Advanced Manufacturing,
Propulsion System Studies and Additional Testing Capability. In addition the combination of budget
constraints and the CSTI emphasis on validated technology starves the program of new technologies.
MAJOR TECHNICAL/PROGRAMMATIC ISSUES." Several propulsion options are available to the U.S. for
the next generation of vehicles. The ETO program must maintain a broad base of technology to address a
range of options. In addition, the absence of Program Advanced Development programs makes the ETO
program the Nation's propulsion Advanced Development Program by default.
What Earth-To-Orbit Does Not Address
TOPIC COMMENTS
• Aerospike nozzle
• Airbreathing/Combined
Cycle
• Storable propellants
• Hybrid propulsion
• Pressure fed
• Small study efforts
• SDIO is spendingsignificant funds
on Aerospike SSTO
• NASP Program
• OEAT Workshop is plannned
• No identified requirement
• Commercial program; augmented
for '95
Residual activity at MSFC, no
further work planned after
current contracts expire
128
B9
B14
B18
BI9
B20
B22
B23
B24
Blade Tip Rubb;ng Stress Prediction
SlnJcluraf Damping Prediction
Methods
Delection ol Degradation in
Tud0omachlnecy Bearings
Acoustic Characleristics ol
Tudoomachlnery cavities
High Frequency Flow/SIructure
Interaction
Turbine Blade-Damper Analysis
DynamOs of Bearings Components
Dynamics Analysis Program
MSFC Structural Dynamics
Summary
PdorIFYg0]FY91 FY9_ FYg: FY94 FY95
Producl
Verified Method for PradiCling Blade Tip Rubbing Stress
I
1
1
1
I
I
I ]
I
I
I
I I
Summary o! SSME Measured Damping Charaderistics
I Test Vedfied Method of Identifying Bearing Signatures
Prediction Method Io_ Acoustic Response ol Turbomachinery
Cavities
] Method lot Predicting Flow/SIn.mture Interaclion
AnafysL_l Capabflily fo_ Large Blade-Damper Systems
Method for Predicting the Dynamic Motion ol Bearing Balls &
Cage
Implement a Universally Acceplable General Purpose
Aria fysis Code
B 15(A)
B14(C)
el 5(F)
B15(G)
B16
Probabillstic Structural
Analysis Methods
Analysis/Tailoring
Coupled Fluid/Structure
Interaction
Probabilistic Fracture
Finite Elements
Composite Load Spectra
LeRC Structural Dynamics
Working Group Summary
IP 'l  l "i '21
_N
7
Product
Methods/Codes for Reliability & Risk
Contract/Grants Code Validation & Concept
Demonstration
Methods/Codes Hot Fluid/Structure Interaction
Methods/Codes for Probabilistic Fracture
Methods/Codes for Probabilistic Loads Simulation
129
MI Hydrogen Alloy Developmenl
Oetelmlnat_,_ of Ignl1_n
M2a Temperalures and Burning Rates In
High Pressure Oxygen
M_"b Oxidation of Mateda_ in High
Pressure Oxygen
M2C Coefflclent of Friction
fm,let_etlona
Mea FtacfUt_ll Charaofet_tk_l of Slng_)
Crystal Blade Maledela
M4b Evaluatlon luxI Characterization of
SinglQ Cn/stal Materlak
MS8 Devetopment of e New Cage MatedaV
Composite for Cryogenic Beadnge
Mt 9e Development of New Mater(sis for
Cryogenic Tur'oopump Beadngs
Mlgb DevetopmenJ of Fracture Tough end
Cotroslon Resistant Beedng M_et_ll
M20 Crac_ Growth in Turtx>pump Bearing
Matedab
M22 Duc_kl CoMings for Hydrog_
Embfittlemont PTotlc'tlon
M23 Hydrogen Tesl Standardization
M27 .Superp_aatlc and So,d-State Jolnt, ng
Proceae Development
MSFC Materials
Development/Evaluation
Working Group Summary
I I I I I
[ [ _t Cheract edzafion Cornl_e_e
_J_
-F- l-T-
_ I
_! I I I
Io
- • _,onverted to In-House
_lniliate Component Validation
o,.,,oT.o,v.,,-I
---- -- --'_!eartn Mode_ DevelOped
I
I I t I I [
I I. 1 .I '1 I
Product
Weldable. H_gh SIrangth. Cohesion Resistent StPJcturet
Alloy Wilh Immunity to Hy_ogon Eff_'ls
[DevelOp Theoretical Understanding of Fundamental Oxl_t)o_
Prociss In HIeh Pressure Oxygen
I Develop Methodology for Evalu_ding Materials Undergoing
Oxidation In High P_ssu_/1"enlperetu_ Etl_ronrt,_nts
Develop • Test System tO Evaluate the Co_lflclerd of Fdctldn of
Metet_ele in High f_t_iuf_ Oxy_e,n
Devek3p Methodok>gy _d Correlates for Fracture Su4aces of
Hydrogen Envkonrnent as I Function of Temperalure,
Pre_u_. and Metedel
Characterization of Odentalion Effects _ PWA 480 as a
Fu_on Of Te,"npe_ture and Env_ronmen!
! Day.fop a 3.000 psi LOX Compatlbb Bearing Cage MatedaJ
Compile Beadng Materbfs Corr4_ar_S_S Accora_ng to
Deveinped Ma|edsts Evaluation C,rlieda
Fo(m*Jlele Fundamental Methodoingy for Development of
Fre, ctunl Tou_h end Corrosion Re_/_tent Cryogenic _e&dogs
Validate Crack Growth Model o_ Defeofe tn Bearing Raceways
DevelOp Due'file Coatings for Hydrogen Prolection of Ag_vanc_d
Propufslon Cortgmnent_ (Over Existing Guldeflnel)
Publish NASA Spectfic.atlon Oullining Guidelines for Meterlale
Testing In High P_e_ure Hy_'ogen
kSlnflfy Matedat_ er_l Proc_u Refinements for }ncotpo_atlon
into Ao*van_ld Propul_lo_ Components
M12 ADVANCED SINGLE CRYSTAL
TURBINE BLADE MATERIALS
M13b FABRICATION PROCESS
DEVELOPMENT FOR W-Re-HI-C
WIRE
M13C FRS ENGINEERING DESIGN
PROPERTY STUDY
M21 HYDROCARBON
FUELS/MATERIALS
COMPATIBILITY
M24 TUNGSTEN/COPPER
COMBUSTION LINER MATERIAL
PROPERTY STUDY
M25 FIBER REINFORCEMENT
COMBUBTION LINER
FABRICATION STUDY
M26 ADVANCEO COPPER ALLOYS
LeRC Materials
Development/Evaluation
Working Group Summary
. Prior F'YgO FYet FY92 FYg3 F'Y94 Product
r-_ _ Advanced single crystal processing techniques to increase
life and reliability o_ turt)opump turbine blades
A demonstraled process for produclio_ of .014 r_'l
W-Fte-HI-C wke for use in W-Wbe reinlorced superalloy
-_--[ turb;ne b_edes
A characlerized _r reinforced superatloy system ready Ior
]]_ scale-up for turbopump turbine blades
Validafed approach to protect MCC cooling channels from
_._ l sulfur corrosion and a method for cooling passage
refu_ishmenl
) A validated computer code Io esSisl in the design of fiber
reinforced coml_sfion chamber liners and c_araclerizafion
of the effect of composite wire o3stribulion on mechanical
end thermal Wop_dies
_._ A luli scale cordoure<l combustion chamber wilh a liner of
refraclory metal w_re reinforced copper alloy capable of
being test fired.
Improved copper.b_se alloys foe _ heal flux applicafion_
130


CSTI Earth-to-orbit propulsion research and technology program overview

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