ALBERT

Description: To aid the J-2X program design effort with detailed performance and environment information, the J-2S fuel turbopump (FTP) inducer has undergone a thorough test series in both water and hydrogen. The test series utilizes both inducer only and a complete pump configuration to assess the inducer interaction to the overall turbopump system. The test goals include verification of suction performance against heritage J-2S data, head production, effects of thermodynamic suppression head (TSH), and evaluation of the inducer dynamic pressure caused by cavitation instabilities. Test facilities at both Pratt & Whitney Rocketdyne (PWR) and NASA s Stennis Space Center (SSC) are employed for the testing. The inducer only water test effort conducted at PWR established performance curves for suction performance, head production, and efficiency over a wide operating range. Because the heritage J-2S suction performance data set is in hydrogen, it is desired to obtain current suction performance data in hydrogen as well, thus avoiding the reliance on a theoretical TSH correlation for direct comparison. This data then provides an empirically based TSH correlation allowing for the comparison of water test suction data to system suction requirements. The FTP testing performed at SSC provides these suction performance relationships as well as inlet duct dynamic pressures during liquid hydrogen operation. The test effort successfully confirms the heritage J-2S suction performance and establishes the amount of TSH between water and hydrogen operation at the design flow coefficient. Correlating data is also obtained for cavitating instability frequency content, illustrating the validity of using the wide flow range water test data to predict hydrogen performance.

Description: The Propulsion and Cryogenics Advanced Development (PCAD) Project in the Exploration Technology Development Program is developing technologies as risk mitigation for Orion and the Lunar Lander. An integrated main and reaction control propulsion system has been identified as a candidate for the Lunar Lander Ascent Module. The propellants used in this integrated system are Liquid Oxygen (LOX)/Liquid Methane (LCH4) propellants. A deep throttle pump fed Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) engine system has been identified for the Lunar Lander Descent Vehicle. The propellant combination and architecture of these propulsion systems are novel and would require risk reduction prior to detailed design and development. The PCAD Project addresses the technology requirements to obtain relevant and necessary test data to further the technology maturity of propulsion hardware utilizing these propellants. This plan and achievements to date will be presented.

Description: Limiting conditions for soot particle inception in spherical diffusion flames were investigated numerically. The flames were modeled using a one-dimensional, time accurate diffusion flame code with detailed chemistry and transport and an optically thick radiation model. Seventeen normal and inverse flames were considered, covering a wide range of stoichiometric mixture fraction, adiabatic flame temperature, and residence time. These flames were previously observed to reach their sooting limits after 2 s of microgravity. Sooting-limit diffusion flames with residence times longer than 200 ms were found to have temperatures near 1190 K where C/O = 0.6, whereas flames with shorter residence times required increased temperatures. Acetylene was found to be a reasonable surrogate for soot precursor species in these flames, having peak mole fractions of about 0.01.

Description: Development of Liquid Rocket Engines is expensive. Extensive testing at large scales usually required. In order to verify engine lifetime, large number of tests required. Limited Resources available for development. Sub-scale cold-flow and hot-fire testing is extremely cost effective. Could be a necessary (but not sufficient) condition for long engine lifetime. Reduces overall costs and risk of large scale testing. Goal: Determine knowledge that can be gained from sub-scale cold-flow and hot-fire evaluations of LRE injectors. Determine relationships between cold-flow and hot-fire data.

Description: The subject of mathematical modeling of the transient operation of liquid rocket engines is presented in overview form from the perspective of engineers working at the NASA Marshall Space Flight Center. The necessity of creating and utilizing accurate mathematical models as part of liquid rocket engine development process has become well established and is likely to increase in importance in the future. The issues of design considerations for transient operation, development testing, and failure scenario simulation are discussed. An overview of the derivation of the basic governing equations is presented along with a discussion of computational and numerical issues associated with the implementation of these equations in computer codes. Also, work in the field of generating usable fluid property tables is presented along with an overview of efforts to be undertaken in the future to improve the tools use for the mathematical modeling process.

Description: The performance of a full-scale translating-spike inlet was obtained at Mach numbers of 1.8 and 2.0 and at angles of attach from 0 deg to 6 deg. Comparisons were made between the full-scale production inlet configuration and a geometrically similar quarter-scale model. The inlet pressure-recovery, cowl pressure-distribution, and compressor-face distortion characteristics of the full-scale inlet agreed fairly well with the quarter-scale results. In addition, the results indicated that bleeding around the periphery ahead of the compressor-face station improved pressure recovery and compressor-face distortion, especially at angle of attack.

Description: The National Aeronautics and Space Administration (NASA) has identified liquid oxygen (LO2)/liquid methane (LCH4) propulsion systems as promising options for some future space vehicles. NASA issued a contract to Aerojet to develop a 100-lbf (445 N) LO2/LCH4 Reaction Control Engine (RCE) aimed at reducing the risk of utilizing a cryogenic reaction control system (RCS) on a space vehicle. Aerojet utilized innovative design solutions to develop an RCE that can ignite reliably over a broad range of inlet temperatures, perform short minimum impulse bits (MIB) at small electrical pulse widths (EPW), and produce excellent specific impulse (Isp) across a range of engine mixture ratios (MR). These design innovations also provide a start transient with a benign MR, ensuring good thrust chamber compatibility and long life. In addition, this RCE can successfully operate at MRs associated with main engines, enabling the RCE to provide emergency backup propulsion to minimize vehicle propellant load and overall system mass.

Description: The complex interactions between internal motor generated pressure oscillations and motor structural vibration modes associated with the static test configuration of a Reusable Solid Rocket Motor have potential to generate significant dynamic thrust loads in the 5-segment configuration (Engineering Test Motor 3). Finite element model load predictions for worst-case conditions were generated based on extrapolation of a previously correlated 4-segment motor model. A modal survey was performed on the largest rocket motor to date, Engineering Test Motor #3 (ETM-3), to provide data for finite element model correlation and validation of model generated design loads. The modal survey preparation included pretest analyses to determine an efficient analysis set selection using the Effective Independence Method and test simulations to assure critical test stand component loads did not exceed design limits. Historical Reusable Solid Rocket Motor modal testing, ETM-3 test analysis model development and pre-test loads analyses, as well as test execution, and a comparison of results to pre-test predictions are discussed.

Description: The NASA New Millennium Program Space Technology 7 (ST7) project will validate technology for precision spacecraft control. The ST7 disturbance reduction system (DRS) will contain new micropropulsion technology to be flown as part of the European Space Agency's LISA (laser interferometer space antenna) Pathfinder project. After launch into a low Earth orbit in early 2010, the LISA Pathfinder spacecraft will be maneuvered to a halo orbit about the Earth-Sun LI Lagrange point for operations. The DRS will control the position of the spacecraft relative to a reference to an accuracy of one nanometer over time scales of several thousand seconds. To perform the control the spacecraft will use a new colloid thruster technology. The thrusters will operate over the range of 5 to 30 micro-Newtons with precision of 0.1 micro-Newton. The thrust will be generated by using a high electric field to extract charged droplets of a conducting colloid fluid and accelerating them with a precisely adjustable voltage. The control position reference will be provided by the European LISA Technology Package, which will include two nearly free-floating test masses. The test mass position and attitude will be sensed and adjusted using electrostatic capacitance bridges. The DRS will control the spacecraft position with respect to one test mass while minimizing disturbances on the second test mass. The dynamic control system will cover eighteen degrees of freedom, six for each of the test masses and six for the spacecraft. In the absence of other disturbances, the test masses will slowly gravitate toward local concentrations of spacecraft mass. The test mass acceleration must be minimized to maintain the acceleration of the enclosing drag-free spacecraft within the control authority of the micropropulsion system. Therefore, test mass acceleration must be predicted by accurate measurement of mass distribution, then offset by the placement of specially shaped balance masses near each test mass. The - acceleration is characterized by calculating the gravitational effect of over ten million modeled points of a nearly 500-kg spacecraft. This paper provides an overview of the mission technology and the process of precision mass modeling of the DRS equipment.

Description: The J-2X program calls for the upgrade of the Apollo-era Rocketdyne J-2 engine to higher power levels, using new materials and manufacturing techniques, and with more restrictive safety and reliability requirements than prior human-rated engines in NASA history. Such requirements demand a comprehensive systems engineering effort to ensure success. Pratt & Whitney Rocketdyne system engineers performed a functional analysis of the engine to establish the functional architecture. J-2X functions were captured in six major operational blocks. Each block was divided into sub-blocks or states. In each sub-block, functions necessary to perform each state were determined. A functional engine schematic consistent with the fidelity of the system model was defined for this analysis. The blocks, sub-blocks, and functions were sequentially numbered to differentiate the states in which the function were performed and to indicate the sequence of events. The Engine System was functionally partitioned, to provide separate and unique functional operators. Establishing unique functional operators as work output of the System Architecture process is novel in Liquid Propulsion Engine design. Each functional operator was described such that its unique functionality was identified. The decomposed functions were then allocated to the functional operators both of which were the inputs to the subsystem or component performance specifications. PWR also used a novel approach to identify and map the engine functional requirements to customer-specified functions. The final result was a comprehensive Functional Flow Block Diagram (FFBD) for the J-2X Engine System, decomposed to the component level and mapped to all functional requirements. This FFBD greatly facilitates component specification development, providing a well-defined trade space for functional trades at the subsystem and component level. It also provides a framework for function-based failure modes and effects analysis (FMEA), and a rigorous baseline for the functional architecture.