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  • 1
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    The 7.5K lbf thrust engine preliminary design for Orbit Transfer Vehicle (1994)
    In:  CASI
    Details
    Publication Date: 2019-06-28
    Description: This document summarizes the preliminary design of the Aerojet version of the Orbit Transfer Vehicle main engine. The concept of a 7500 lbf thrust LO2/GH2 engine using the dual expander cycle for optimum efficiency is validated through power balance and thermal calculations. The engine is capable of 10:1 throttling from a nominal 2000 psia to a 200 psia chamber pressure. Reservations are detailed on the feasibility of a tank head start, but the design incorporates low speed turbopumps to mitigate the problem. The mechanically separate high speed turbopumps use hydrostatic bearings to meet engine life requirements, and operate at sub-critical speed for better throttling ability. All components were successfully packaged in the restricted envelope set by the clearances for the extendible/retractable nozzle. Gimbal design uses an innovative primary and engine out gimbal system to meet the +/- 20 deg gimbal requirement. The hydrogen regenerator and LOX/GH2 heat exchanger uses the Aerojet platelet structures approach for a highly compact component design. The extendible/retractable nozzle assembly uses an electric motor driven jack-screw design and a one segment carbon-carbon or silicide coated columbium nozzle with an area ratio, when extended, of 1430:1. A reliability analysis and risk assessment concludes the report.
    Keywords: SPACECRAFT PROPULSION AND POWER
    Type: AD-A277519 , NASA-CR-189175 , E-8401 , NAS 1.26:189175
    Format: application/pdf
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    NASA TECHNICAL REPORTS
  • 2
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    Integrated control and health management. Orbit transfer rocket engine technology program (1988)
    In:  CASI
    Details
    Publication Date: 2019-06-28
    Description: To insure controllability of the baseline design for a 7500 pound thrust, 10:1 throttleable, dual expanded cycle, Hydrogen-Oxygen, orbit transfer rocket engine, an Integrated Controls and Health Monitoring concept was developed. This included: (1) Dynamic engine simulations using a TUTSIM derived computer code; (2) analysis of various control methods; (3) Failure Modes Analysis to identify critical sensors; (4) Survey of applicable sensors technology; and, (5) Study of Health Monitoring philosophies. The engine design was found to be controllable over the full throttling range by using 13 valves, including an oxygen turbine bypass valve to control mixture ratio, and a hydrogen turbine bypass valve, used in conjunction with the oxygen bypass to control thrust. Classic feedback control methods are proposed along with specific requirements for valves, sensors, and the controller. Expanding on the control system, a Health Monitoring system is proposed including suggested computing methods and the following recommended sensors: (1) Fiber optic and silicon bearing deflectometers; (2) Capacitive shaft displacement sensors; and (3) Hot spot thermocouple arrays. Further work is needed to refine and verify the dynamic simulations and control algorithms, to advance sensor capabilities, and to develop the Health Monitoring computational methods.
    Keywords: SPACECRAFT PROPULSION AND POWER
    Type: NASA-CR-182122 , NAS 1.26:182122 , ATC-2459-42-1
    Format: application/pdf
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    NASA TECHNICAL REPORTS
  • 3
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    Orbital transfer vehicle 3000 LBF thrust chamber assembly hot fire test program (1988)
    In:  CASI
    Details
    Publication Date: 2019-06-28
    Description: The Aerojet Orbital Transfer Vehicle (OTV) Thrust Chamber Assembly (TCA) concept consists of a hydrogen cooled chamber, and annular injector, and an oxygen cooled centerbody. The hot fire testing of a heat sink version of the chamber with only the throat section using hydrogen cooling is documented. Hydraulic performance of the injector and cooled throat were verified by water flow testing prior to TCA assembly. The cooled throat was proof tested to 3000 psia to verify the integrity of the codeposited EF nickel-cobalt closeout. The first set of hot fire tests were conducted with a heat sink throat to obtain heat flux information. After demonstration of acceptable heat fluxes, the heat sink throat was replaced with the LH2 cooled throat section. Fourteen tests were conducted with a heat sink chamber and throat at chamber pressures of 85 to 359 psia. The injector face was modified at this time to add more face coolant flow. Ten tests were then conducted at chamber pressures of 197 to 620 psia. Actual heat fluxes at the higher chamber pressure range were 23 percent higher than the average of 10 Btu/in 2 predicted.
    Keywords: SPACECRAFT PROPULSION AND POWER
    Type: NASA-CR-182145 , NAS 1.26:182145
    Format: application/pdf
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    NASA TECHNICAL REPORTS
  • 4
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    Orbital transfer rocket engine technology: Advanced engine study (1992)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: An advanced LOX/LH2 engine study for the use of NASA and vehicle prime contractors in developing concepts for manned missions to the Moon, Mars, and Phobos is documented. Parametric design data was obtained at five engine thrusts from 7.5K lbf to 50K lbf. Also, a separate task evaluated engine throttling over a 20:1 range and operation at a mixture ratio of 12 plus or minus 1 versus the 6 plus or minus 1 nominal. Cost data was also generated for DDT&E, first unit production, and factors in other life cycle costs. The major limitation of the study was lack of contact with vehicle prime contractors to resolve the issues in vehicle/engine interfaces. The baseline Aerojet dual propellant expander cycle was shown capable of meeting all performance requirements with an expected long operational life due to the high thermal margins. The basic engine design readily accommodated the 20:1 throttling requirement and operation up to a mixture ratio of 10 without change. By using platinum for baffled injector construction the increased thermal margin allowed operation up to mixture ratio 13. An initial engine modeling with an Aerojet transient simulation code (named MLETS) indicates stable engine operation with the baseline control system. A throttle ratio of 4 to 5 seconds from 10 percent to 100 percent thrust is also predicted. Performance predictions are 483.1 sec at 7.5K lbf, 487.3 sec at 20K lbf, and 485.2 sec at 50K lbf with a mixture ratio of 6 and an area ratio of 1200. Engine envelopes varied from 120 in. length/53 in. exit diameter at 7.5K lbf to 305 in. length/136 in. exit diameter at 50 K lbf. Packaging will be an important consideration. Continued work is recommended to include more vehicle prime contractor/engine contractor joint assessment of the interface issues.
    Keywords: SPACECRAFT PROPULSION AND POWER
    Type: NASA-CR-187216 , NAS 1.26:187216 , AEROJET-2459-31-1 , AD-A253786
    Format: application/pdf
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    NASA TECHNICAL REPORTS
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