NASA's Vision for Exploration requires a safe, reliable, affordable upper stage engine to power the Ares I Crew Launch Vehicle (CLV) and the Ares V Cargo Launch Vehicle. The J-2X engine is being developed for that purpose, epitomizing NASA's philosophy of employing legacy knowledge, heritage hardware, and commonality to carry the next generation of explorers into low-Earth orbit and out into the solar system This presentation gives top-level details on accomplishments to date and discusses forward work necessary to bring the J-2X engine to the launch pad

Byrd, Thomas D.

Kynard, Michael .

NASA Technical Reports Server

_Progress onth~Upper Stage Engine for the Ares
I Crew Launch Vehicle and the Ares V Cargo Launch
Vehicle
Thomas D. Byrd, Deputy Manager, and Michael H. Kynard, Manager
Upper Stage Engine Element Office
Ares Projects Office
NASA Marshall Space Flight Center
Huntsville, AL 35812
Presentation Abstract
NASA's Vision for Exploration requires a safe, reliable, affordable upper stage engine to power the Ares I Crew
Launch Vehicle (CLY) and the Ares V Cargo Launch Vehicle. The J-2X engine is being developed for that purpose,
epitomizing NASA's philosophy of employing legacy knowledge, heritage hardware, and commonality to carry the
next generation of explorers into low-Earth orbit and out into the solar system This presentation gives top-level
details on accomplishments to date and discusses forward work necessary to bring the J-2X engine to the launch
pad.
https://ntrs.nasa.gov/search.jsp?R=20070037456 2019-08-30T02:04:41+00:00Z

Agenda
• Overview of the Ares Launch Vehicles and mission
• J-2X heritage and design evolution
• Current design requirements and status
• 2006-2007 progress
• Forward work and conclusions
National Aeronautics and Space Administration 7281.2
Overview of the
Exploration Launch Projects Architecture
• Safe, reliable, affordable space transportation
• Based on heritage hardware and legacy knowledge
• Separates cargo from crew
• Ares V (left) delivers heavy exploration cargo to Low Earth Orbit
• Ares I (right) delivers crew and cargo to LEO, International Space Station
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Ares Launch Vehicles to
Support Exploration
Ares I
52k Ibm to LEO
• Ares V
- Core Stage
• 5 RS-68 LOxlLH2 Core Stage engines
.2 Ares I-derived RSRBs
- Earth Departure Stage (EDS)
• 1 J-2X LOxlLH2 Upper Stage Engine
• Common hardware and procedures with
Ares I to reduce development and
operations costs
• Shared heritage, shared hardware
• Ares I
1 Shuttle-derived Reusable Solid
Rocket Booster (RSRB) First Stage
1 J-2X LOxlLH2 Upper Stage Engine
2 S-5egment RSRBs
Core Stage
LOxlLHz
S RS-68 Engines
AJ-Li Tanks/Structures
Composite Shroud
Earth Departure Stage
LOxlLHz
1 J-2X Engine
AI-Li Tanks/
Composite Structures
Lunar
Lander
} Inle..tage
Ares V
143 Ibm* to TLI in
Dual-Launch Mode with Ares I
284k Ibm to LEO
First Stage
(S-5egment RSRB)
Upper Stage
Instrument Unit
Launch Abort System
~ Interstage
_ Orion Crew Exploration Vehicle
(Crew Module / Service Module)
Forward Frustum
Spacecraft Adapter
J-2X Upper Stage Engine
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The Lunar Mission Scenario
Ascent
Stage
Expended
... ·..1·..·· ..··· ..··· ....·..·..
- -
'7
,
................... .,
,
Service
Module
Low :4 EXp'ended
....1;~J1'1. --..;~---....r;----+-_ .
Orbit
11'-
Lunar Lander
100 km Performs LOI
Low Lunar Orbit· .. ·· .. ········· .. ·· .. ···························.. ····· ..... ,
E
.
,
:t-
Vehicles Not
to Scale
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J·2X Development Philosophy
• One Engine
• From the beginning, the goal has been to undertake a single engine development
cycle in order to fulfill the needs of both Ares I and Ares V.
• Requirements Driven
• This is a flight hardware development project, not a technology development effort.
• Engine capabilities and characteristics are pursued because they exist as
architecture requirements.
• Leverage Heritage Hardware and Legacy Knowledge
• A significant reduction in overall project risk expected through the utilization of J-2,
J-2S, and RS-68 experience and the relatively recent XRS-2200 development.
• Thus, the goal is to leverage heritage designs and experience to the maximum
extent practical.
• Aggressive Schedule
• Because the engine is expected to be the critical path for the vehicle, the approach is
to pursue an extremely aggressive schedule.
• Early Risk Reduction
• An element of the aggressive schedule is to include risk reduction testing at
component and subsystem level (where it makes sense) as early as possible to guide
the overall development of the engine.
• Schedule risk mitigated by adding spare hardware and using 3 test facilities for
engine hot fire.
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J-2X Requirements and Parameters
Nominal Vacuum Thrust
• Nominal = 294k
• Open-loop control
Mixture Ratio
• Nominal = 5.5
• Open-loop control
Altitude Start and Orbital Re-Start
• Start at > 100,000 ft.
• Second start after 100 day on orbit
Secondary Mode Operation
• Thrust = -82%
• MR = 4.5
• Vacuum Thrust 240 klbf
Natural and Induced Environments
• First-stage loads on Ares I
• In-space environments for Ares V
Engine Gimbal
• 4-degree square
• Drives design of flexible inlet ducts and
gimbal block
Health and Status Monitoring and Reporting
Data Collection for Post-Flight Analysis
Engine Failure Notification
• Drives towards controller versus sequencer
• Drives software development and V&V
Minimum Vacuum Isp =448 sec
• Drives size of nozzle extension
• Drives increased need for altitude simulation
test facility
• Nozzle Area Ratio 92:1
National Aeronautics and Space Administration
Operational Life =4 starts and 2,000 seconds (post-delivery)
7281.7
J-2X Description
• Propellants - Liquid Hydrogen and Liquid Oxygen
• High energy
• Gas-generator cycle
• Same cycle as that used for J-2, F-1, RS-68, and many other engines
• Simple to develop and operate
• Not as intrinsically efficient as staged-combustion or expander cycle
• Two turbopumps (Oxygen/Hydrogen)
• No boost pumps
• Powered by single, fuel-rich gas generator
• Turbines arranged in series with exhaust dumped into nozzle
• Very large diverging nozzle and high performance main injector
• To achieve performance comparable to staged-combustion engine
• Pneumatic valve actuation
• Spring-loaded so as to provide for safe shutdown in the event of loss of electrical
power or pneumatic pressure
• On-board engine controller
• Start-up and shut down pre-programmed
• Open-loop control - does not actively control to mixture ratio and power level
• Controls to commanded operational points (two points)
• Engine health monitoring (shut down if over "redline")
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J·2X Heritage Features
HIP-bonded MCC
• Based on RS-68
demonstrated technology
Valves
• Ball-sector traceable to XRS-2200
and RS-68
Nozzle Extension
• Based on RL10-B2 experience
Open-Loop Pneumatic Control
• Similar to J-2 & J-2S design
Gimbal Block
• Based on J-2 &J-2S design
• Potential upgrade to more modern, demonstrated materials
Flexible Inlet Ducts
• Based on J-2 & J-2S ducts
• Adjusted to meet J-2X performance
• Altered to meet current NASA design
standards
Heat Exchanger
• Based on J-2 experience on
as used on S-IVB
Tube-Wall Regeneratively-
Cooled Nozzle Section
• Based on long history of
RS-27 success (Delta 11/111)
Engine Controller
• Based on directly on RS-68
design and software architecture
Gas Generator
• Based on RS-68 design
• Scaled to meet J-2X needs
Turbomachinery
• Based on J-2S MK-29 design
• Beefed up to meet J-2X performance
• Altered to meet current NASA design
standards
The J-2X engine is based on heritage systems with directly traceable flight experience.
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J-2X Engine Layout
Fluid Interface Panel
National Aeronautics and Space Administration
Oxidizer Turbine
Bypass Valve
(OTBV)
Turbine
Exhaust Gas
Manifold
Oxidizer
Inlet Duct
Regen
Nozzle
Nozzle-__
Extension
Fuel Inlet Duct
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J-2X System Development Plan Overview
CY 2006 2007 2008 2009 2010 2011 2012 2013 2014
i1estones
Level 5 Milestones
MSFC
Testing
SSC A-1
"A-2 like" stand
(passive diffuser, 550 sec
duration, TMS)
SSC A-3
Engine Tests
L.....,_---IFlight Controller Test
Ares 1-Y Orion 1Projected Launch Milestones \7 \7
I Mass Sim E10006 (NEO
Engine Need Dates E10002 for MPTA E10006 for Orion 1
..."',o§>\#" ,#' ,#' ,;o§>\). #" #': o§>' OCR
PPk 2 Test
~.&.-_--...;;------~
Stand Prep
Stand Build
CDR
\7
J-2X Engine DDT&E
",-~_....... Workhorse Gas Generator Tests
I I
_____,......__...ITurbopump Water &Air Tests
I
Prototype
Controller Test
Tear Down
Heritage Valves
& Turborum.
_40K Injector TestsD
Design
ATP PRR SRRlSDR PDR
~~ ~
SL MPTA MSFC 4670
I
Shaker Facility (boost phase sim)
~Complete \7Projected Completion
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Progress: Smoke and Fire
• J-2X subscale injector
testing at MSFC,
2006-2007
• 32 J-2X-focused tests
• 28-, 40-, and 58-element
inserts
• Thrust levels: less than
20,0001bf
• Chamber pressures: 850-
1,500 psig
• Mixture Ratios: 4.8 to 6.9
• Fuel manifold
temperatures: 100 to 300
degrees Rankin
• Other components to be
tested: gas generator,
turbopumps, and igniters
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National Aeronautics and Space Administration
Progress: Powerpack 1-A Assembly,
Test Stand A-1 Handover
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Progress: Resync Review Selects
Composite Nozzle
J-2X RL108-2
~
,-~
:=:='~,~
~""""I .A, ~~
II
!l···._.
• 3D Naxeco Carbon-Carbon composite skirt from SPS with modular PWR TEG design
• Best balance of technical margin, application readiness and affordability
• Significant weight advantage and thermal risk mitigation vs. metallic designs
• Based on the RL1OB-2 flight proven configuration
• Two cone configuration to improve manufacturing throughput and reduce
manufacturing risk.
• The J-2X nozzle extension will be the largest shell nozzle extension for a liquid
rocket engine created to date
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Progress: Altitude Test Facility Decision
Stennis Space Center A-Complex
A·1 test stand
A·3 test site
layout
A·2 test stand
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Progress: Test Facilities - Continued
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Test Stand A-3 Site Preparation July '07
Groundbreaking August '07
Facility Activation Summer 2010
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Test Stand A-2 Handover
National Aeronautics and Space Administration
• J·2X schedule reflects July 2009
handover, early 2010 testing
• SSME and J·2X will meet in
March 2009 for final decision
7281.18
Recent Developments
• DDT&E Contract: Pratt & Whitney Rocketdyne, ATP July 16,2007, $1.2
billion, ground and test flight engines, extends through Design
Certification Review in December 2012
• Additional development hardware: 1 assembled engine, 1 unassembled
spare, 4 sets of long lead hardware through first 18 months of 36-month
manufacturing cycle.
• Successful PDR August 2007: system safety, software development work
needed before July 2008 Critical Design Review
• 52-element subscale main injector, workhorse gas generator,
turbomachinery water flow and air flow tests at MSFC under way or
pending
• Powerpack 1-A installation pending for first test phase in November
• Nozzle extension delta PDR fall 2007, Naxeco to Novoltex material change
pending due to material availability, subcontract pending with Snecma
• Draft Interface Control Document with Upper Stage, maturing toward Upper
Stage PDR May 2008
• Aggressively maturing design for long lead hardware for Powerpack 2 and
first engine tests
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J-2X Summary
• The J-2X will be the workhorse upper
stage engine for the next generation of
space exploration
• The overarching intent is to keep the
engine as simple as possible while still
fulfilling the challenging performance
requirements imposed
• Based almost entirely on Technology
Readiness Level =9 technology
• Development schedule is short and
already quite active with PDR
completed August 2007 and CDR
scheduled for August 2008
National Aeronautics and Space Administration 7281.20
More Information/Conclusion
• Thomas D. Byrd
Thomas.D.Byrd@NASA.Gov
(256) 544·7147
• Ares public website: www.nasa.gov/ares
• Questions?
National Aeronautics and Space Administration 7281.21


Progress on the J-2X Upper Stage Engine for the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle

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