Hill, Jerry

Morehead, Rob

NASA Technical Reports Server

Integrated Cryogenic Propulsion Test Article 
and Thermal Vacuum Hotfire
Test Results Overview
JANNAF In-Space Propulsion TIM
JSC Propulsion
April 6, 2017
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https://ntrs.nasa.gov/search.jsp?R=20170002908 2019-08-30T16:33:24+00:00Z
• LOX/Methane spacecraft prototype
– Built at JSC in 2016 for this thermal vacuum environment 
– New components and hardware from the former Morpheus vehicle and other projects
– Integrated into Plum Brook ISPF in Dec/Jan
– First Hotfire test at ISPF: Feb 3, 2017
• 6 Weeks of testing at ISPF
– Dozens of RCS, ME, ME+RCS, loading, chill, thermal tests
– Ambient temp / deep thermal, High altitude / vacuum
– Joint operations: PB operated environment and prop loading, JSC operated vehicle
• JSC, KSC, GRC, SSC team focused on LOX/Methane research and other experiments
Integrated Cryogenic Propulsion Test Article (ICPTA)
2
• Lander configuration (tested w/o legs), central main engine, pod-mounted 
reaction control engines on vehicle perimeter
• 4x 48” spherical tanks (2ea. LOX / Methane) insulated with MLI + aerogel
• Common plumbing for main and RCS engines, insulated with MLI + aerogel
• RCS engines:  Two pods (7lbf + 28lbf in each)
– Coil-on-Plug ignition, 85:1 nozzles
– Gas/Gas, Gas/Liquid, Liquid/Liquid operation; 100msec g SS ops
• Main Engine
– 2,800 lbf Vac, 5:1 throttling, thrust measurement system
– Coil-on-plug (COP) ignition, O2/CH4 igniter, 100:1 composite ablative nozzle 
• Helium Pressurization
– COPV with vac rated foam + MLI, LN2 cooling systems
– High pressure HEX on ME Nozzle, warm gas reg panel, flowmeters, diffusers in prop tanks
• Flight computer external to test cell w/50-ft harness
• 320+ static/dynamic sensors on vehicle: temp, press, accel, load, strain, mics, etc
• Piezoelectric Mass Propellant Gauging (MPG) system
• CFM Experiments: Internal Tank Chill, facility/vehicle cryo loading heat transfer
• 4 load cell interface for vehicle to structure: real-time weight
• Multiple heaters on vehicle and around test cell
• Fluids: 4800 lbm LOX, 1800 lbm Methane, 7lb helium
• Checkout hotfire test at JSC in Dec, 2016
ICPTA Design Overview
3
Test Objectives Overview
4
• Provide ME and RCS thrust for Plum Brook facility characterization
• Collect LOX/Methane vehicle model validation data for a variety of 
experiments
– System-level model verification: RCS manifold transient fluids, ME+RCS 
dynamics, vehicle thermal, cold helium pressurization / ullage collapse
– Subsystem model verification: RCEs/ME performance, Tank/Line insulation, 
Modal propellant mass gauging, Methane heat transfer, Tank chill, internal 
tank chill system
• Subsystem demonstration: coil-on-plug ignition, facility nozzle diffuser 
(w/blowback), others
• Analysis and model results will be reported at the 2017 AIAA JPC
Numerous math models: fluids, thermal, SS/transient
On OffOff
Typical Manifold Dynamics 
During TVAC RCS Test, 
LOX/LCH4
• Accomplishments for test campaign, LOX/Methane research, and tech development:
Plum Brook Test Campaign Results
5
TVAC Hotfire of 7lbf Jet
3/9/17
– Multiple main engine tests up to 55 sec duration, 
sufficient to characterize the Plum Brook facility
– 800+ Reaction Control Engine ignitions: numerous 
system operational modes including self-priming
• Vehicle RCS hotfires at thermal vacuum conditions 
(First) with thermal-related no-lights observed
– Modal Propellant Mass Gauging performance data 
collected during hotfire and propellant 
loading/draining (First)
– Cryo Fluid Management: Line/Tank chill heat transfer 
data collected for liquid methane (First) and liquid 
oxygen/nitrogen;  demonstrated vehicle methane tank 
spray cooling system (First)
– Coil-on-Plug ignition system tested at vehicle level in 
high corona risk range (First)
– Cold Helium Pressurization of a cryo propellant at 
flight-like conditions
– Numerous other minor experiments
ICPTA Combo hotfire test, 2/28/17
National Aeronautics and Space Administration
www.nasa.gov
Backup
6
Modal Propellant Gauge (MPG) System
-Z LOX Tank with PZT patch sensors/actuator 7
• Orion Mass gauging experiment for Orion and AES
– KSC conducting under MOA with Orion and AES
• Propellant mass measurements
– Non-intrusive sensor bonded to outside of a propellant tank 
that measures the mass inside
– Capable of zero-g and 1 g mass measurement
• Zero-g flights of small tank have shown good results
– Open question of system performance under engine vibration
• Test Objective
– Gather data during hot-fire at sea level and altitude conditions 
to understand engine vibration/acoustic effects on 
measurements
– Measure any differential draining that occurs
• Installed on two LO2 tanks (not methane)
– Gather data during loading/unloading to gauge 0-99% fill 
levels
• Test Plan
– Install PZT sensors on two LOX tanks and vehicle structure
– Perform modal tap checks of installed system
– Collect data during sea level hotfires at JSC and altitude 
hotfires at Plum Brook with and without actuator powered
• Main Engine and RCS only operation desired


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