ALBERT

Description: Experience with many spacecraft configurations boosted by a variety of launch vehicles indicates that the maximum loads experienced throughout most of the structure are inertial in origin. These loads arise from the dynamic elastic response of the flight vehicle to the transient disturbances of launch and flight, and are highly dependent on the dynamic characteristics of both the spacecraft and the launch vehicle. It has proved to be most advantageous, in the analysis of this critical dependency of loads upon vehicle dynamic properties, to establish a mathematical model in terms of normal mode characteristics. In this way, the vibration behavior of an elastomechanical structure (or substructure) can be described by means of the so-called modal or natural degrees of freedom. The conduct of a mode survey test and the use of a suitably test-verified model in loads analyses is essential to the flight worthiness certification process of space systems. The desirability of such tests is confirmed by the fact that, almost invariably, significant deficiencies in the analytical models are revealed by the results. Therefore, this experimental program was undertaken to determine those properties of a solid-propellant rocket motor (SRM) which are required to characterize a dynamic model. Random ambient-excited accelerations were measured at a series of stations along the motor for the purpose of identifying the motor beam-like stiffnesses in bending, shear, and torsion. From a system identification point of view, it is significant that stiffness properties of a subsystem (the motor) are determined from modes of the full system (motor/stand configuration) using mode shape data of the subsystem only. This contrasts with traditional system identification approaches which rely upon complete system mode shapes.

Description: The orbiting shadowing analysis computer program was developed by NASA in order to assess the shadowing effects on various power systems. The algorithms, the inputs and outputs are discussed. Examples of typical shadowing analysis, performed for the International Space Station Freedom, the International Space Station Alpha and the joint United States/International Mir Solar Dynamic Flight Experimental Project are presented.

Description: The topics addressed are: (1) phobos power plant; (2) fusion power/propulsion system; (3) surface power from an orbiting spacecraft; (4) RTG replacement; (5) MHD-thermoelectric burst reactor; (6) TAU Voyage power/propulsion device; (7) ESCAPE to ODYSSEY.

Description: The Texas A&M Nuclear and Aerospace engineering departments have worked on five different projects for the NASA/USRA Advanced Design Program during the 1987/88 year. The aerospace department worked on two types of lunar tunnelers that would create habitable space. The first design used a heated cone to melt the lunar regolith, and the second used a conventional drill to bore its way through the crust. Both used a dump truck to get rid of waste heat from the reactor as well as excess regolith from the tunneling operation. The nuclear engineering department worked on three separate projects. The NEPTUNE system is a manned, outer-planetary explorer designed with Jupiter exploration as the baseline mission. The lifetime requirement for both reactor and power-conversion systems was twenty years. The second project undertaken for the power supply was a Mars Sample Return Mission power supply. This was designed to produce 2 kW of electrical power for seven years. The design consisted of a General Purpose Heat Source (GPHS) utilizing a Stirling engine as the power conversion unit. A mass optimization was performed to aid in overall design. The last design was a reactor to provide power for propulsion to Mars and power on the surface. The requirements of 300 kW of electrical power output and a mass of less than 10,000 Rg were set. This allowed the reactor and power conversion unit to fit within the Space Shuttle cargo bay.

Description: A contactless method for the determination of the free-carrier density and the composition distribution across the thickness of 3-5 multi-layer solar cell structures, using the Raman scattering method, is developed. The method includes a step analysis of Raman spectra from optical phonons and phonon-plasmon modes of different layers. The method provides simultaneous measurements of the element composition and the thickness of the structure's layers together with the free-carrier density. The results of measurements of the free-carrier density composition distributions of the liquid phase epitaxy grown AlGaAs/GaAs and GaSb solar cell structures are presented and discussed.

Description: The photovoltaic array space power (PASP)-Plus solar cell flight experiment is described, and the observed performances of different solar cell types during the first six months of their operation, are summarized. The solar cell types include single crystal and amorphous silicon, GaAs, several multijunction cell types, indium phosphide and GaAs/GaSb concentrator cells. The radiation degradation experienced by some of the solar cell types agrees with theoretical predictions. Other samples, including silicon, are degraded less than predicted. Effects, including the increase in temperature of all the experiments and the effect of sun glint on cell measurement, are discussed.

Description: The conceptual design and experimental results for two types of space application concentrator photovoltaic modules, employing reflective optical elements, are presented. The first type is based on the use of compound parabolic concentrators, the second type is based on the use of line-focus parabolic troughs. Lightweight concentrators are formed with nickel foil coated silver with a diamond-like carbon layer protection. Secondary optical elements, including lenses and cones, are introduced for a better matching of concentrators and solar cells. Both types of modules are characterized by concentration ratios in the range 20x to 30x, depending on the chosen range of misorientation angles. The estimated specific parameters of these modules operating with single junction AlGaAs/GaAs solar cells are 240 W/sq m and 3 kg/sq m.

Description: Two contact systems for use on shallow junction InP solar cells are described. The feature shared by these two contact systems is the absence of the metallurgical intermixing that normally takes place between the semiconductor and the contact metallization during the sintering process. The n(+)pp(+) cell contact system, consisting of a combination of Au and Ge, not only exhibits very low resistance in the as-fabricated state, but also yields post-sinter resistivity values of 1(exp -7) ohms-sq cm, with effectively no metal-InP interdiffusion. The n(+)pp(+)cell contact system, consisting of a combination of Ag and Zn, permits low resistance ohmic contact to be made directly to a shallow junction p/n InP device without harming the device itself during the contacting process.

Description: The effects of irradiation of In(0.53)Ga(0.47)As/InP (InGaAs/InP) solar cells illuminated through a transparent InP substrate with 1 MeV electrons were measured. These solar cells were developed for bottom cells in tandem solar photovoltaic cell structures. Some InGaAs/InP heterostructures with four layers were grown by liquid phase epitaxy. The structure of the solar cells allowed lightly doped materials in n and p photoactive layers to be used. The base dopant levels ranged from 1.10(exp 17) to 5.10(exp 17) cm(exp -3). The open circuit voltage and the short circuit current were moderately degraded after irradiation with 10(exp 16) cm(exp-2) 1 MeV electrons. This behavior is explained in terms of the device structure and the n and p layer thicknesses.

Description: The relationship between the exploration of space and the availability of abundant power supplies is discussed. It is proposed that nuclear power will be needed to satisfy the power demands of manufacturing facilities in LEO, and power demands for the year 2000 are projected to be 300 KW(e). The capabilities and development of the Space Station are described; the use of nuclear power for the Station and various reactor location configurations are studied. The power requirements that will be necessary for the development of lunar resource bases and the exploration of Mars and other planets are considered; the advantages of nuclear power are examined.

Description: An evaluation is made of technology development prospects for launch vehicle, orbit transfer vehicle, satellite, and planetary exploration spacecraft propulsion systems being contemplated by NASA and its research contractors. Attention is given to such electric propulsion systems as arcjet, pulsed plasma, ion, and resistojet thrusters, as well as to solar thermal heat exchanger powerplants, beamed energy propulsion systems, and ultra-advanced nuclear fission and fusion propulsion concepts.

Description: A brief summary is presented of a NASA study contract and in-house investigation on Growth Space Station missions and appropriate nuclear and solar space electric power systems. By the year 2000 some 300 kWe will be needed for missions and housekeeping power for a 12 to 18 person Station crew. Several Space Station configurations employing nuclear reactor power systems are discussed, including shielding requirements and power transmission schemes. Advantages of reactor power include a greatly simplified Station orientation procedure, greatly reduced occultation of views of the earth and deep space, near elimination of energy storage requirements, and significantly reduced station-keeping propellant mass due to very low drag of the reactor power system. The in-house studies of viable alternative Growth Space Station power systems showed that at 300 kWe a rigid silicon solar cell array with NiCd batteries had the highest specific mass at 275 kg/kWe, with solar Stirling the lowest at 40 kg/kWe. However, when 10 year propellant mass requirements are factored in, the 300 kWe nuclear Stirling exhibits the lowest total mass.

Description: Two propulsion systems have been selected for the Space Station: O/H rockets for high thrust applications and the multipropellant resistojets for low thrust needs. These thruster systems integrate very well with the fluid systems on the station. Both thrusters will utilize waste fluids as their source of propellant. The O/H rocket will be fueled by electrolyzed water and the resistojets will use stored waste gases from the environmental control system and the various laboratories. This paper presents the results of experimental efforts with O/H and resistojet thrusters to determine their performance and life capability.

Description: Reflective surfaces for Space Station power generation systems are required to withstand the atomic oxygen-dominated environment of near earth orbit. Thin films of platinum and rhodium, which are corrosion resistant reflective metals, have been deposited by ion beam sputter deposition onto various substrate materials. Solar reflectances were then measured as a function of time of exposure to a RF-generated air plasma.

Description: The development of a three-dimensional inelastic analysis methodology for the Space Shuttle main engine (SSME) structural components is described. The methodology is composed of: (1) composite load spectra, (2) probabilistic structural analysis methods, (3) the probabilistic finite element theory, and (4) probabilistic structural analysis. The methodology has led to significant technical progress in several important aspects of probabilistic structural analysis. The program and accomplishments to date are summarized.

Description: Extraterrestrial resources for space processing of chemicals, in general, and propellants, in particular, are explored quantitatively. It is seen that, for several candidate space mission scenarios, space processing of both space resources and earth-carried resources can make decisive differences in the mission success for a given payload. To fix ideas and demonstrate trends, the specific case of water splitting to extract oxygen, discard (or use without storage) the resulting hydrogen, and burn earth-carried noncryogenic liquid fuel(s) in a simple rocket motor, designed for periodic thrusting, is treated in some detail. Experimental hardware is assembled and demonstrated to perform adequately, besides showing compactness of the space-packaged 'capsule' module that is self-contained. Building upon previous studies, the concept of in situ propellant production (ISPP) is reexamined in light of more recent energy and materials technologies. Missions to comets and Mars Sample Return are mentioned as candidate scenarios. The mission duration, reliability-repairability of hardware, resource availability in low earth orbit (LEO), and the thrust requirements are considered in turn. It is seen that space storage of hydrogen for extended durations (5-10 years) involves problems that require detailed studies, besides involving many presently unanswered issues. A study of the energy option in LEO and in deep space is developed in simple terms. The different solar, radioisotope, and nuclear power sources are mentioned. Storage and handling of raw and processed chemicals are considered.

Description: The design and performance of a arcjet nuclear electric propulsion spacecraft, suitable for use in a space reactor power system (SRPS) flight experiment, are outlined. The vehicle design is based on a 92-kW ammonia arcjet system operating at a specific impulse of 1050 s and an efficiency of 45 percent. The arcjet/gimbal system, power processing unit, and propellant feed system are described. A 100-kW SRPS is assumed and the spacecraft mass is baselined at 5250 kg, excluding the propellant and propellant feed system. A radiation/arcjet efflux diagnostics package is included in the performance analysis. This spacecraft, assuming a Shuttle launch from Kennedy Space Center, can perform a 35-deg inclination change and reach a final orbit of 35,860 km with a 120-day trip time, thus providing a four-month active load for the SRPS. Alternatively, a Titan IV launch could provide a mass margin of 120 kg to a 1000km, 58-deg final orbit in 74 days.

Description: The major requirements and guidelines that affect the manned Space Station configuration and the power systems are explained. The evolution of the Space Station power system from the NASA program development feasibility phase through the current preliminary design phase is described. Several early station concepts are described and linked to the present concept. The recently completed phase B tradeoff study selections of photovoltaic system technologies are described. The present solar dynamic and power management and distribution systems are also summarized for completeness.

Description: A new concept for a Space Station power system is proposed which reduces the drag effect of the solar panels and eliminates eclipsing by the Earth. The solar generator is physically separated from the Space Station, and power transmitted to the station by a microwave beam. The power station can thus be placed high enough that drag is not a significant factor. For a resonant orbit where the ratio of periods s:p is a ratio of odd integers, and the orbital planes nearly perpendicular, an orbit can be chosen such that the line of sight is never blocked if the lower orbit has an altitude greater than calculatable mininum. For the 1:3 resonance, this minimum altitude is 0.5 r(e). Finally, by placing the power station into a sun-synchronous orbit, it can be made to avoid shadowing by the Earth, thus providing continuous power.

Description: A brief history of the development of electrical power systems from the earliest manned space flights illustrates a natural trend toward a growth of electrical power requirements and operational lifetimes with each succeeding space program. A review of the design philosophy and development experience associated with the Space Shuttle Orbiter electrical power system is presented, beginning with the state of technology at the conclusion of the Apollo Program. A discussion of prototype, verification, and qualification hardware is included, and several design improvements following the first Orbiter flight are described. The problems encountered, the scientific and engineering approaches used to meet the technological challenges, and the results obtained are stressed. Major technology barriers and their solutions are discussed, and a brief Orbiter flight experience summary of early Space Shuttle missions is included. A description of projected Space Station power requirements and candidate system concepts which could satisfy these anticipated needs is presented. Significant challenges different from Space Shuttle, innovative concepts and ideas, and station growth considerations are discussed. The Phase B Advanced Development hardware program is summarized and a status of Phase B preliminary tradeoff studies is presented.

Description: The rudiments of a rocket thruster that receives its enthalpy from a remote energy source, a laser, are described. An experimental study is discussed that provides details of the physics for assessing the feasibility of using hydrogen plasmas for accepting and converting this energy to enthalpy. A plasma ignition scheme that uses a pulsed CO2 laser has been developed and the properties of the ignition spark documented, including breakdown intensities in hydrogen. A complete diagnostic system, capable of determining plasma temperature and the plasma absorptivity for subsequent steady-state absorption of a high-power CO2 laser beam, is developed and demonstrative use is discussed for the preliminary case study, a 2 atm laser-supported argon plasma.

Description: Aluminum oxide particles from the exhaust of the Space Shuttle were collected immediately after the launch of the SEPEX mission and during the descent over the altitude interval of 7.6-4.6 km. The SEM examination revealed that the particles were spherical and ranged in diameter from about 0.1 micron to 10 microns. Results from the energy dispersive analysis (by an X-ray method) and of the particle chemistry (by electron spectroscopy) confirmed that the particles were predominantly composed of aluminum and oxygen. The particle size distribution of the Al2O3 was bimodal, with one observed peak centered near 2.0 microns; the other distribution mode centered at a diameter of less than 0.3 micron, but could not be accurately located. A mass median diameter was slightly less than 2 microns. Evaluation of ice nucleation activity revealed only a small fraction (about 1 ppm) of active ice nuclei among the Al2O3 particulates.

Description: The main objective of this study is to develop a new test method that is suitable for the assessment of the resistance of aerospace cables to arc tracking for different specific environmental and network conditions of spacecrafts. This paper reports the purpose, test conditions, test specimen, test procedure, and test acceptance criteria of seven different (200-250 mm long) cables.

Description: This report contains viewgraphs on arc tracking tests in various aerospace environments. It has the following six sections: LeRC arc tracking tests parameters, apparatus, sample description, procedure, arc tracking test results, and discussion.

Description: The results of the testing of wire insulation materials for space applications is presented in this report. The wire insulations tested were partially fluorinated polyimide, extruded ETFE, extruded PTFE, PTFE tape, and PTFE/Kapton. The tests performed were flammability tests, odor tests, compatibility tests with aerospace fluids, offgassing tests, and thermal vacuum stability tests.

Description: The objectives of the NASA Wiring for Space Applications program were to investigate the effects of atomic oxygen (AO), ultraviolet (UV) radiation, and AO with UV synergistic effects on wire insulation materials. The AO exposure was on the order of 10(exp 21) atoms/sq cm and the vacuum UV radiation was on the order of 10,000 ESH. The results of these tests are presented in this document

Description: The electrical power wiring tests results from the NASA Wiring for Space Applications program are presented. The goal of the program was to develop a base for the building of a lightweight, arc track-resistant electrical wiring system for aerospace applications. This new wiring system would be applied to such structures as pressurized modules, trans-atmospheric vehicles, LEO/GEO environments, and lunar and Martian environments. Technological developments from this program include the fabrication of new insulating materials, the production of new wiring constructions, an improved system design, and an advanced circuit protection design.

Description: Oxidizer propellant systems for liquid-fueled rocket engines must meet stringent cleanliness requirements for particulate and nonvolatile residue. These requirements were established to limit residual contaminants which could block small orifices or ignite in the oxidizer system during engine operation. Limiting organic residues in high pressure oxygen systems is particularly important. The current method of cleanliness verification used by Rocketdyne requires an organic solvent flush of the critical hardware surfaces. The solvent is filtered and analyzed for particulate matter, followed by gravimetric determination of the nonvolatile residue (NVR) content of the filtered solvent. The organic solvents currently specified for use (1,1,1-trichloroethane and CFC-113) are ozone-depleting chemicals slated for elimination by December 1995. A test program is in progress to evaluate alternative methods for cleanliness verification that do not require the use of ozone-depleting chemicals and that minimize or eliminate the use of solvents regulated as hazardous air pollutants or smog precursors. Initial results from the laboratory test program to evaluate aqueous-based methods and organic solvent flush methods for NVR verification are provided and compared with results obtained using the current method. Evaluation of the alternative methods was conducted using a range of contaminants encountered in the manufacture of rocket engine hardware.

Description: The Solid Rocket Motors (SRM) used by NASA to propel the Space Shuttle employ gimballing nozzles as a means for vehicular guidance during launch and ascent. Gimballing a nozzle renders the pressure field of the exhaust gases nonaxisymmetric. This has two effects: (1) it exerts a torque and side load on the nozzle; and (2) the exhaust gases flow circumferentially in the aft-dome region, thermally loading the flexible boot, case-to-nozzle joint, and casing insulation. The use of CFD models to simulate such flows is imperative in order to assess SRM design. The grids for these problems were constructed by obtaining information from drawings and tabulated coordinates. The 2D axisymmetric grids were designed and generated using the EZ-Surf and GEN2D surface and grid generation codes. These 2D grids were solved using codes such as FDNS, GASP, and MINT. These axisymmetric grids were rotated around the center-line to form 3D nongimballed grids. These were then gimballed around the pivot point and the gaps or overlaps resurfaced to obtain the final domains, which contained approximately 366,000 grid points. The 2D solutions were then rotated and manipulated as appropriate for geometry and used as initial guesses in the final solution. The analyses were used in answering questions about flight criteria.

Description: A two-year feasibility and test program to solve the problem of unburned confined hydrogen at the Vandenberg Space Launch Complex Six (SLC-6) during Space Shuttle Main Engine (SSME) firings is discussed. A novel steam inerting design was selected for development. Available sound suppression water is superheated to flash to steam at the duct entrance. Testing, analysis, and design during 1987 showed that the steam inerting system (SIS) solves the problem and meets other flight-critical system requirements. The SIS design is complete and available for installation at SLC-6 to support shuttle or derivative vehicles.

Description: The development of probabilistic structural analysis methods is a major part of the SSME Structural Durability Program and consists of three program elements: composite load spectra, probabilistic finite element structural analysis, and probabilistic structural analysis applications. Recent progress includes: (1) the effects of the uncertainties of several factors on the HPFP blade temperature pressure and torque, (2) the evaluation of the cumulative distribution function of structural response variables based on assumed uncertainties on primitive structural variables, and (3) evaluation of the failure probability. Collectively, the results obtained demonstrate that the structural durability of critical SSME components can be probabilistically evaluated.

Description: Vehicle/engine analysis studies have identified the High/Dual Mixture Ratio O2/H2 Engine cycle as a leading candidate for an advanced Single Stage to Orbit (SSTO) propulsion system. This cycle is designed to allow operation at a higher than normal O/F ratio of 12 during liftoff and then transition to a more optimum O/F ratio of 6 at altitude. While operation at high mixture ratios lowers specific impulse, the resultant high propellant bulk density and high power density combine to minimize the influence of atmospheric drag and low altitude gravitational forces. Transition to a lower mixture ratio at altitude then provides improved specific impulse relative to a single mixture ratio engine that must select a mixture ratio that is balanced for both low and high altitude operation. This combination of increased altitude specific impulse and high propellant bulk density more than offsets the compromised low altitude performance and results in an overall mission benefit. Two areas of technical concern relative to the execution of this dual mixture ratio cycle concept are addressed. First, actions required to transition from high to low mixture ratio are examined, including an assessment of the main chamber environment as the main chamber mixture ratio passes through stoichiometric. Secondly, two approaches to meet a requirement for high turbine power at high mixture ratio condition are examined. One approach uses high turbine temperature to produce the power and requires cooled turbines. The other approach incorporates an oxidizer-rich preburner to increase turbine work capability via increased turbine mass flow.

Description: Characterization of liquid rocket engine injector elements is an important part of the development process for rocket engine combustion devices. Modern nonintrusive instrumentation for flow velocity and spray droplet size measurement, and automated, computer-controlled test facilities allow rapid, low-cost evaluation of injector element performance and behavior. Application of these methods in rocket engine development, paralleling their use in gas turbine engine development, will reduce rocket engine development cost and risk. The Alternate Turbopump (ATP) Hot Gas Systems (HGS) preburner injector elements were characterized using such methods, and the methodology and some of the results obtained will be shown.

Description: Recent hot fire testing at the Marshall Space Flight Center (MSFC) has indicated the swirl-coaxial element to be a viable candidate for the STBE injector. Plans are to test the current 40K lbf thrust injector at the higher chamber pressure and colder fuel temperature which are anticipated for STBE. A cold flow program to characterize the swirl coax element over a range of operating points was conducted. The results are presented and compared to the hot fire data. Predictions for compatibility, performance and stability are then presented for the uprated test conditions.

Description: A LOX/LH2 high/variable mixture ratio booster upper stage is described. The engine has high thrust-weight ratio as a booster and high specific impulse as an upper stage engine. Operation at high mixture ratio utilizes the propellants at high bulk density. The engine may use multiple turbopump-preburners for higher thrust ratings. The engine uses the full flow cycle to obtain minimum turbine inlet temperatures for a given chamber pressure and to avoid interpropellant shaft seals and other single point failure modes. A portion of the liquid hydrogen is used to regeneratively cool the thrust chamber assembly. The warmed hydrogen coolant is then used to drive the fuel boost turbopump. All propellants arrive at the gas-gas injector ready to burn. Shear mixing of the parallel flowing high velocity, low density fuel-rich gases with the high density, low velocity oxidizer-rich gases provides complete combustion with a modest chamber volume. Combustion stability is assured by the injection of the heated fuel-rich gases and the comparatively low volume ratio of the propellants before and after combustion. The high area ratio nozzle skirt is fitted with a low area ratio nozzle skirt insert for optimum low altitude performance. The overall engine characteristics make it a candidate for ALS, Shuttle-C, LRB, and SSTO applications.

Description: Two thermal design improvements for 30 kWe arcjet engines are described. A ZrB2 high temperature coating was used to increase the surface emissivity of the nozzle radiating surface, enabling lower temperature operation, which should lead to longer nozzle life. The ZrB2-coated engine operated 120 C cooler than the uncoated baseline engine indicating a 30 percent increase in the surface emissivity. An engine design which has fewer active seals than previous designs and operates at lower overall component temperatures is described. The nozzle on the engine operated at 1950 C at 30 kWe while the baseline engine nozzle reached 2000 C at 23 kWe. The back of the engine was more than a factor of two cooler when compared to the baseline engine.

Description: The anode and cathode of a 30 kW class arcjet engine were sectioned and analyzed. This arcjet was operated for a total time of 573 hr at power levels between 25 and 30 kW with ammonia at flow rates of 0.25 and 0.27 gm/s. The accumulated run time was sufficient to clearly establish erosion patterns and their causes. The type of electron emission from various parts of the cathode surface was made clear by scanning electron microscope analysis. A scanning electron microscope was used to study recrystallization on the hot anode surface. These electrodes were made of 2 percent thoriated tungsten and the surface thorium content and gradient perpendicular to the surfaces was determined by quantitative microprobe analysis. The results of this material analysis on the electrodes and recommendations for improving electrode operational life time are presented.

Description: The model of the system assumes a constant power source and loads (experiments) whose power demands exceed the supply. Experiments are described by their name, power consumption, time for a complete run, present status and the state of the load. The power consumption of each load is set at a constant level but can be dynamically modified by the operator. The status specifies if the experiment is running, paused, completed or failed. The state compensates for the lack of actual feedback sensor data, by signifying the stability of the load. Experiments are scheduled to keep as many running as possible with the current system limitations. A graphics oriented user interface is embedded into the rule-based system to enable an operator to easily experiment with the system.

Description: In order to evaluate Space Shuttle Main Engine (SSME) vibration data without having to constantly replay analog tapes, the SSME Vibration Data Base was developed. This data base contains data that have been digitized at a high sample rate for the entire test duration. It provides quick and efficient recall capabilities for numerious computation and display routines. The data base components are described as well as some of the compution and display features.

Description: This paper is a survey of the waste minimization efforts of industries outside of aerospace for possible applications in the manufacture of solid rocket motors (SRM) for NASA. The Redesigned Solid Rocket Motor (RSRM) manufacturing plan was used as the model for processes involved in the production of an SRM. A literature search was conducted to determine the recycling, waste minimization, and waste treatment methods used in the commercial sector that might find application in SRM production. Manufacturers, trade organizations, and professional associations were also contacted. Waste minimization efforts for current processes and replacement technologies, which might reduce the amount or severity of the wastes generated in SRM production, were investigated. An overview of the results of this effort are presented in this paper.

Description: The numerical model for a rocket thermal analysis code (RTE) is discussed. RTE is a comprehensive thermal analysis code for thermal analysis of regeneratively cooled rocket engines. The input to the code consists of the composition of fuel/oxidant mixture and flow rates, chamber pressure, coolant temperature and pressure. dimensions of the engine, materials and the number of nodes in different parts of the engine. The code allows for temperature variation in axial, radial and circumferential directions. By implementing an iterative scheme, it provides nodal temperature distribution, rates of heat transfer, hot gas and coolant thermal and transport properties. The fuel/oxidant mixture ratio can be varied along the thrust chamber. This feature allows the user to incorporate a non-equilibrium model or an energy release model for the hot-gas-side. The user has the option of bypassing the hot-gas-side calculations and directly inputting the gas-side fluxes. This feature is used to link RTE to a boundary layer module for the hot-gas-side heat flux calculations.

Description: In view of the complex flight operation of the Space Shuttle propulsion system together with an expected launch rate increase, the flight performance reconstruction process needs to be performed by automated computer programs. These programs must have the capability to quickly and reliably determine the true behavior of the various components of the propulsion system. For the flight reconstruction, measured values from the solid rocket motors, liquid engines, and trajectory are appraised through the Kalman filter technique to identify the most likely flight propulsion performance. A more detailed data collection program for the single SSME engine captive test firing evaluation is scheduled for startup in September of 1988. Engine performance evaluation for the captive test firing requires a reconstruction process that is similar to the process that is used for the flight reconstruction. Analytical tools that may be used to reconstruct a propulsion system's true performance under flight and/or test conditions are described.

Description: The effects of radiation on the performance of modern rocket propulsion systems operating at high pressure and temperature were recognized as a key issue in the design and operation of various liquid rocket engines of the current and future generations. Critical problem areas of radiation coupled with combustion of bipropellants are assessed and accounted for in the formulation of a universal scaling law incorporated with a radiation-enhanced vaporization combustion model. Numerical algorithms are developed and the pertaining data of the Variable Thrust Engine (VTE) and Space Shuttle Main Engine (SSME) are used to conduct parametric sensitivity studies to predict the principal intercoupling effects of radiation. The analysis reveals that low enthalpy engines, such as the VTE, are vulnerable to a substantial performance set back by the radiative loss, whereas the performance of high enthalpy engines such as the SSME, are hardly affected over a broad range of engine operation. Additionally, combustion enhancement by the radiative heating of the propellant has a significant impact in those propellants with high absorptivity. Finally, the areas of research related with radiation phenomena in bipropellant engines are identified.

Description: A number of computer codes are available for performing thermal analysis of solid rocket motor nozzles. Aerotherm Chemical Equilibrium (ACE) computer program can be used to perform one-dimensional gas expansion to determine the state of the gas at each location of a nozzle. The ACE outputs can be used as input to a computer program called Momentum/Energy Integral Technique (MEIT) for predicting boundary layer development development, shear, and heating on the surface of the nozzle. The output from MEIT can be used as input to another computer program called Aerotherm Charring Material Thermal Response and Ablation Program (CMA). This program is used to calculate oblation or decomposition response of the nozzle material. A code called Failure Analysis Nonlinear Thermal and Structural Integrated Code (FANTASTIC) is also likely to be used for performing thermal analysis of solid rocket motor nozzles after the program is duly verified. A part of the verification work on FANTASTIC was done by using one and two dimension heat transfer examples with known answers. An attempt was made to prepare input for performing thermal analysis of the CCT nozzle using the FANTASTIC computer code. The CCT nozzle problem will first be solved by using ACE, MEIT, and CMA. The same problem will then be solved using FANTASTIC. These results will then be compared for verification of FANTASTIC.

Description: The user of computational fluid dynamics (CFD) codes must be concerned with the accuracy and efficiency of the codes if they are to be used for timely design and analysis of complicated three-dimensional fluid flow configurations. A brief discussion of how accuracy and efficiency effect the CFD solution process is given. A more detailed discussion of how efficiency can be enhanced by using a few Cray Research Inc. utilities to address vectorization is presented and these utilities are applied to a three-dimensional Navier-Stokes CFD code (INS3D).

Description: One of the key components of the Advanced Launch System (ALS) is a large liquid rocket, booster engine. To keep the overall vehicle size and cost down, this engine will probably use liquid oxygen (LOX) and a heavy hydrocarbon, such as RP-1, as propellants and operate at relatively high chamber pressures to increase overall performance. A technology program (Heavy Hydrocarbon Main Injector Technology) is being studied. The main objective of this effort is to develop a logic plan and supporting experimental data base to reduce the risk of developing a large scale (approximately 750,000 lb thrust), high performance main injector system. The overall approach and program plan, from initial analyses to large scale, two dimensional combustor design and test, and the current status of the program are discussed. Progress includes performance and stability analyses, cold flow tests of injector model, design and fabrication of subscale injectors and calorimeter combustors for performance, heat transfer, and dynamic stability tests, and preparation of hot fire test plans. Related, current, high pressure, LOX/RP-1 injector technology efforts are also briefly discussed.

Description: The design and performance of a spacecraft employing arcjet nuclear electric propulsion, suitable for use in the SP-100 Space Reactor Power System (SRPS) Flight Experiment, are outlined. The vehicle design is based on a 93 kW(e) ammonia arcjet system operating at an experimentally measured specific impulse of 1031 s and an efficiency of 42.3 percent. The arcjet/gimbal assemblies, power conditioning subsystem, propellant feed system, propulsion system thermal control, spacecraft diagnostic instrumentation, and the telemetry requirements are described. A 100 kW(e) SRPS is assumed. The spacecraft mass is baselined at 5675 kg excluding the propellant and propellant feed system. Four mission scenarios are described which are capable of demonstrating the full capability of the SRPS. The missions considered include spacecraft deployment to possible surveillance platform orbits, a spacecraft storage mission, and an orbit raising round trip corresponding to possible orbit transfer vehicle (OTV) missions.

Description: A concept in electrodeless plasma propulsion, which is also capable of delivering a variable Isp, is presented. The concept involves a three-stage system of plasma injection, heating, and subsequent ejection through a magnetic nozzle. The nozzle produces the hybrid plume by the coaxial injection of hypersonic neutral gas. The gas layer, thus formed, protects the material walls from the hot plasma and, through increased collisions, helps detach it from the diverging magnetic field. The physics of this concept is evaluated numerically through full spatial and temporal simulations; these explore the operating characteristics of such a device over a wide region of parameter space. An experimental facility to study the plasma dynamics in the hybrid plume was built. The device consists of a tandem mirror operating in an asymmetric mode. A later upgrade of this system will incorporate a cold plasma injector at one end of the machine. Initial experiments involve the full characterization of the operating envelope, as well as extensive measurements of plasma properties at the exhaust. The results of the numerical simulations are described.

Description: Three dimensional nonlinear finite element heat transfer and structural analyses were performed for the first stage high pressure fuel turbopump (HPFTP) blade of the space shuttle main engine (SSME). Directionally solidified (DS) MAR-M 246 and single crystal (SC) PWA-1480 material properties were used for the analyses. Analytical conditions were based on a typical test stand engine cycle. Blade temperature and stress strain histories were calculated by using the MARC finite element computer code. The structural response of an SSME turbine blade was assessed and a greater understanding of blade damage mechanisms, convective cooling effects, and thermal mechanical effects was gained.

Description: Space shuttle main engine (SSME) blades are subject to severe thermal, pressure, and forced vibration environments. Structural optimization provides an automated alternative to time consuming iterations. Any number of analyses, design variables, and constraints can be incorporated in a structural optimization computer code. This idea was applied to develop the code SSME/STAEBL, which is a stand alone code suitable for automated design of SSME turbopump blades. Additions and modifications of STAEBL included in SSME/STAEBL include the following: (1) thermal stress analysis, (2) gas dynamic (pressure) loads, (3) temperature-dependent material and thermal properties, (4) forced vibrations, (5) tip displacement constraints, (6) single crystal material analysis, (7) blade cross-section stacking offsets, and (8) direct time integration algorithm for transient dynamic response.

Description: The high frequency data acquisition system developed for the Space Shuttle Main Engine (SSME) single engine test facility at the National Space Technology Laboratories is discussed. The real time system will provide engineering data for a complete set of SSME instrumentation (approx. 100 measurements) within 4 hours following engine cutoff, a decrease of over 48 hours from the previous analog tape based system.

Description: A technique of obtaining particle size information from holograms of combustion products is described. The holograms are obtained with a pulsed ruby laser through windows in a combustion chamber. The reconstruction is done with a krypton laser with the real image being viewed through a microscope. The particle size information is measured with a Quantimet 720 image processing system which can discriminate various features and perform measurements of the portions of interest in the image. Various problems that arise in the technique are discussed, especially those that are a consequence of the speckle due to the diffuse illumination used in the recording process.

Description: NASA Lewis Research Center is currently developing probabilistic structural analysis methods for select Space Shuttle Main Engine (SSME) structural components. Briefly, the deterministic, three-dimensional, inelastic analysis methodology developed under the Hot Section Technology (HOST) and R and T Base Programs is being augmented to accommodate the complex probabilistic loading spectra, the thermoviscoplastic material behavior, and the material degradation associated with the environment of space propulsion system structural components representative of the SSME such as turbine blades, transfer ducts, and liquid-oxygen posts. The development of probabilistic structural analysis methodology consists of the following program elements: (1) composite load spectra; (2) probabilistic structural analysis methods; (3) probabilistic finite element theory - new variational principles; and (4) probabilistic structural analysis application. In addition, the program includes deterministic analysis elements: (1) development of structural tailoring computer codes (SSME/STAEBL); (2) development of dynamic creep buckling/ratcheting theory; (3) evaluation of the dynamic characteristics of single-crystal SSME blades; (4) development of SSME blade damper technology; and (5) development of integrated boundary elements for hotfluid structure interaction.

Description: A brief overview of statistical tools needed to perform post flight/test reconstruction of state variables is given. Linear regression, recursive linear regression, and the exact connection between the Kalman filter and linear regression are discussed. The regression connection is expected to serve as an aid in the application of a recently developed analytical method of flight reconstruction to single engine test firing data.

Description: Arguments are presented for the retention of vibrational equilibrium of species in the nozzle of the Space Shuttle Main Engine which are especially applicable to water and the hydroxyl radical. It is shown that the reaction OH + HH yields HOH + H maintains equilibrium as well. This is used to relate OH to H, the temperature, and the oxidizer-to-fuel ratio.

Description: A boundary integral representation for a coupled approach to fluid flow and solid deformation problems associated with the design of hot-section components such as those in the Space Shuttle Main Engine is discussed. The formulation is based on the fundamental analytical solution of the Navier-Stokes equation for fluid velocity in an infinite domain. This fundamental solution was obtained by decomposing a Navier-Stokes equation into vorticity and dilation transport equations. A boundary integral involving convolutions in time was then constructed in which the convective terms appear in the volume integral.

Description: Before 1975 turbine blade damper designs were based on experience and very simple mathematical models. Failure of the dampers to perform as expected showed the need to gain a better understanding of the physical mechanism of friction dampers. Over the last 10 years research on friction dampers for aeronautical propulsion systems has resulted in methods to optimize damper designs. The first-stage turbine blades on the Space Shuttle Main Engine (SSME) high-pressure oxygen pump have experienced cracking problems due to excessive vibration. A solution is to incorporate a well-designed friction dampers to attenuate blade vibration. The subject study, a cooperative effort between NASA Lewis and Carnegie-Mellon University, represents an application of recently developed friction damper technology to the SSME high-pressure oxygen turbopump. The major emphasis was the contractor's design known as the two-piece damper. Damping occurs at the frictional interface between the top half of the damper and the underside of the platforms of the adjacent blades. The lower half of the damper is an air seal to retard airflow in the volume between blade necks.

Description: Space Shuttle Main Engine/Structural Tailoring of Engine Blades (SSME/STAEBL) was developed by systematically modifying and enhancing the STAEBL code developed by Pratt and Whitney under contract to NASA Lewis Research Center. STAEBL was designed for application to gas turbine blade design. Typical design variables include blade thickness distribution and root chord. Typical constraints include resonance margins, root stress, and root to chord ratios. In this program, the blade is loaded by centrifugal forces only. Additions and modifications of STAEBL included in SSME/STAEBL include (1) thermal stress analysis; (2) gas dynamic (pressure) loads; (3) temperature dependent material and thermal properties; (4) forced vibrations; (5) tip displacement constraints; (6) single crystal material analysis; (7) blade cross section stacking offsets; and (8) direct time integration algorithm for transient dynamic response. Capabilities are also included which permit data transfer from finite element models and stand-alone analysis.

Description: A major task of the program to develop an expert system to predict the loads on selected components of a generic space propulsion engine is the design development and application of a probabilitic loads model. This model is being developed in order to account for the random nature of the loads and assess the variable load ranges' effect on the engine performance. A probabilistic model has been developed. The model is based primarily on simulation methods, but also has a Gaussian algebra method (if all variables are near normal), a fast probability integrator routine (for the calculation of low probability events), and a separate, stand alone program for performing barrier crossing calculations. Each of these probabilistic methods has been verified with theoretical calculations using assumed distributional forms.

Description: To quantify the uncertainties associated with the geometry and material properties of a Space Shuttle Main Engine (SSME) turbopump blade, a computer code known as STAEBL was used. A finite element model of the blade used 80 triangular shell elements with 55 nodes and five degrees of freedom per node. The whole study was simulated on the computer and no real experiments were conducted. The structural response has been evaluated in terms of three variables which are natural frequencies, root (maximum) stress, and blade tip displacements. The results of the study indicate that only the geometric uncertainties have significant effects on the response. Uncertainties in material properties have insignificant effects.

Description: The purpose is to develop models of random impacts on a Space Shuttle Main Engine (SSME) turbopump blade and to predict the probabilistic structural response of the blade to these impacts. The random loading is caused by the impact of debris. The probabilistic structural response is characterized by distribution functions for stress and displacements as functions of the loading parameters which determine the random pulse model. These parameters include pulse arrival, amplitude, and location. The analysis can be extended to predict level crossing rates. This requires knowledge of the joint distribution of the response and its derivative. The model of random impacts chosen allows the pulse arrivals, pulse amplitudes, and pulse locations to be random. Specifically, the pulse arrivals are assumed to be governed by a Poisson process, which is characterized by a mean arrival rate. The pulse intensity is modelled as a normally distributed random variable with a zero mean chosen independently at each arrival. The standard deviation of the distribution is a measure of pulse intensity. Several different models were used for the pulse locations. For example, three points near the blade tip were chosen at which pulses were allowed to arrive with equal probability. Again, the locations were chosen independently at each arrival. The structural response was analyzed both by direct Monte Carlo simulation and by a semi-analytical method.

Description: Advanced structural reliability methods are utilized on the Probabilistic Structural Analysis Methods (PSAM) project to provide a tool for analysis and design of space propulsion system hardware. The role of the effort at the University of Arizona is to provide reliability technology support to this project. PSAM computer programs will provide a design tool for analyzing uncertainty associated with thermal and mechanical loading, material behavior, geometry, and the analysis methods used. Specifically, reliability methods are employed to perform sensitivity analyses, to establish the distribution of a critical response variable (e.g., stress, deflection), to perform reliability assessment, and ultimately to produce a design which will minimize cost and/or weight. Uncertainties in the design factors of space propulsion hardware are described by probability models constructed using statistical analysis of data. Statistical methods are employed to produce a probability model, i.e., a statistical synthesis or summary of each design variable in a format suitable for reliability analysis and ultimately, design decisions.

Description: Propulsion requirements for launch vehicles, upper stages, satellites and platforms, and planetary spacecraft are described from a functional perspective and compared on an energy basis. Mission velocity requirements for a range of missions are presented. A simple model relating optimum exhaust velocity and maximum system delta-V as a function of system-specific energy is developed, which provides insight into the relationship between system performance and various power and propulsion subsystem characteristics. Based on this model, various advanced propulsion options, e.g., the solid-core nuclear rocket and nuclear electric propulsion, are evaluated, and the implications of this analysis for propulsion and power system technology development programs are discussed. The objective of this paper is to provide an overview of future propulsion requirements for the nonspecialist.

Description: The workshop was oriented to disclose information and unsettled problems to understand the fundamental physical mechanism of the droplet formation process. Based on presentation and discussion of results, recommendations were made which should lead to associated future activities. To accomplish this task, existing observations and experiments, contributing to the basic knowledge, providing data for analytical concept verification, and forming a basis for empirical correlations were solicited. Advanced analytical modeling methods or results from specific studies were requested as well as the experience and advice from injector designers. All effort is directed to advance current analytical techniques, simulating the flow behavior downstream of the injection elements in a liquid rocket combustion chamber. Such a tool can be used to optimize injector designs with respect to short length weight savings, wall material protection, or large heat energy transport to a regenerative cooling fluid, while simultaneously achieving the maximum specific impulse in performance. The liquid atomization process also forms a sound basis for combustion instability analysis.

Description: A preliminary uncertainty analysis was performed for the High Area Ratio Rocket Nozzle test program which took place at the altitude test capsule of the Rocket Engine Test Facility at the NASA Lewis Research Center. Results from the study establish the uncertainty of measured and calculated parameters required for the calculation of rocket engine specific impulse. A generalized description of the uncertainty methodology used is provided. Specific equations and a detailed description of the analysis is presented. Verification of the uncertainty analysis model was performed by comparison with results from the experimental program's data reduction code. Final results include an uncertainty for specific impulse of 1.30 percent. The largest contributors to this uncertainty were calibration errors from the test capsule pressure and thrust measurement devices.

Description: Future space vehicles and platforms including Space Station will possess complex power systems. These systems will require a high level of autonomous operation to allow the crew to concentrate on mission activities and to limit the number of ground support personnel to a reasonable number. The Electrical Power Branch at NASA-Marshall is developing advanced automation approaches which will enable the necessary levels of autonomy. These approaches include the utilization of knowledge based or expert systems.

Description: The ability to accurately characterize propellant in a finite element model is a concern of engineers tasked with studying the dynamic response of the Space Shuttle Solid Rocket Motor (SRM). THe uncertainties arising from propellant characterization through specimem testing led to the decision to perform a model survey and model correlation of a single segment of the Shuttle SRM. Multiple input methods were used to excite and define case/propellant modes of both an inert segment and, later, a live propellant segment. These tests were successful at defining highly damped, flexible modes, several pairs of which occured with frequency spacing of less than two percent.

Description: The major requirements and guidelines that affect the space station configuration and power system are explained. The evolution of the space station power system from the NASA program development-feasibility phase through the current preliminary design phase is described. Several early station concepts are described and linked to the present concept. Trade study selections of photovoltaic system technologies are described in detail. A summary of present solar dynamic and power management and distribution systems is also given.

Description: Considerable opportunity exists to improve the systems, subsystems, components, etc., included in the space station bus, the non-payload portion of the spacecraft. The steps followed to date, the challenges being faced by industry, and the progress toward establishing a new NASA initiative which will identify the technologies required to build spacecraft of the 21st century and which will implement the technology development/validation programs necessary are described.

Description: The specific energy density and the performance of nickel electrodes are generally limited by the electrode microstructure and the nature of the active material within the electrode matrix. Progress is being made in our laboratory in a collaborative effort with NASA-LEWIS Research Center to develop lighter weight, mechanically stable and highly efficient nickel electrodes for aerospace applications. Our approach is based on an electrode microstructure fabricated from a mixture of nickel fibers as small as 2 micro m diameter and cellulose fibers. Results will be presented to show the optimum conditions for impregnating this electrode microstructure with nickel hydroxide active material. Performance data in half-cell tests and cycle life data will also be presented. The flexibility of this electrode microstructure and the significant advantages it offers in terms of weight and performance will be demonstrated, in particular its ability to accept charge at high rates and to discharge at high rates.

Description: The deep space and planetary exploration project have been acquiring more and more importance and some of them are now well established both in ESA and NASA programs. This paper presents the possibility to utilize both silicon and gallium arsenide solar cells as spacecraft primary power source for missions far from the Sun, in order to overcome the drawbacks related to the utilisation of radioisotope thermoelectric generators - such as cost, safety and social acceptance. The development of solar cells for low illumination intensity and low temperature (LILT) applications is carried out in Europe by ASE (Germany) and CISE (Italy) in the frame of an ESA programme, aimed to provide the photovoltaic generators for ROSETTA: the cometary material investigation mission scheduled for launch in 2003. The LILT cells development and testing objectives are therefore focused on the following requirements: insolation intensity as low as 0.03 Solar Constant, low temperature down to -150 C and solar flare proton environment. At this stage of development, after the completion of the technology verification tests, it has been demonstrated that suitable technologies are available for the qualification of both silicon and gallium arsenide cells and both candidates have shown conversion efficiencies over 25% at an illumination of 0.03 SC and a temperature of -150 C. In particular, when measured at those LILT conditions, the newly developed 'Hl-ETA/NR-LILT' silicon solar cells have reached a conversion efficiency of 26.3%, that is the highest value ever measured on a single junction solar cell. A large quantity of both 'Hl-ETA/NR-LILT' silicon and 'GaAs/Ge-LILT' solar cells are presently under fabrication and they will be submitted to a qualification test plan, including radiation exposure, in order to verify their applicability with respect to the mission requirements. The availability of two valid options will minimize the risk for the very ambitious scientific project. The paper describes how the technical achievements have been possible with Si and GaAs LILT solar cells (including a comparison between measured and modelled l-V characteristics) and it presents the technology verification tests results.

Description: A method and apparatus of manufacturing a grid member for use in an ion discharge apparatus provides a woven carbon fiber in a matrix of carbon. The carbon fibers are orientated to provide a negatibe coefficient of thermal expansion for at least a portion of the grid member's operative range of use.

Description: This report presents the results obtained from an experimental analysis of the flow field in the slots of the star grain section in the head-end of the advanced solid rocket motor during the ignition transient. This work represents an extension of the previous tests and analysis to include the effects of using a center port in conjunction with multiple canted igniter ports. The flow field measurements include oil smear data on the star slot walls, pressure and heat transfer coefficient measurements on the star slot walls and velocity measurements in the star slot.

Description: The main objective of this test was to obtain detailed radial and circumferential flow surveys at the inlet and exit of the SSME High Pressure Fuel Turbine model using three-hole cobra probes, hot-film probes, and a laser velocimeter. The test was designed to meet several objectives. First, the techniques for making laser velocimeter, hot-film probe, and cobra probe measurements in turbine flows were developed and demonstrated. The ability to use the cobra probes to obtain static pressure and, therefore, velocity had to be verified; insertion techniques had to be established for the fragile hot-film probes; and a seeding method had to be established for the laser velocimetry. Once the measurement techniques were established, turbine inlet and exit velocity profiles, temperature profiles, pressure profiles, turbulence intensities, and boundary layer thicknesses were measured at the turbine design point. The blockage effect due to the model inlet and exit total pressure and total temperature rakes on the turbine performance was also studied. A small range of off-design points were run to obtain the profiles and to verify the rake blockage effects off-design. Finally, a range of different Reynolds numbers were run to study the effect of Reynolds number on the various measurements.

Description: A solar thermal upper stage (STUS) is envisioned as a propulsive concept for the future. The STUS will be used for low Earth orbit (LEO) to geostationary-Earth orbit (GEO) transfer and for planetary exploration missions. The STUS offers significant performance gains over conventional chemical propulsion systems. These performance gains translate into a more economical, more efficient method of placing useful payloads in space and maximizing the benefits derived from space activity. This paper will discuss the economical advantages of an STUS compared to conventional chemical propulsion systems, the potential market for an STUS, and the recent activity in the development of an STUS. The results of this assessment combined with the performance gains, will provide a strong justification for the development of an STUS.

Description: The Optical Plume Anomaly Detection (OPAD) system is under development to provide early-warning failure detection in support of ground-level testing of the Space Shuttle Main Engine (SSME). Failure detection is to be achieved through the acquisition of spectrally resolved plume emissions and subsequent identification of abnormal levels indicative of engine corrosion or component failure. Two computer codes (one linear and the other non-linear) are used by the OPAD system to iteratively determine specific element concentrations in the SSME plume, given emission intensity and wavelength information. Since this analysis is extremely labor intensive, a study was initiated to develop neural networks that would model the 'inverse' of these computer codes. Optimally connected feed-forward networks with imperceptible prediction error have been developed for each element modeled by the linear code, SPECTRA4. Radial basis function networks were developed for the non-linear code, SPECTRA5, and predict combustion temperature in addition to element concentrations.

Description: An assessment of engine and component health is routinely made after each test firing or flight firing of a Space Shuttle Main Engine (SSME). Currently, this health assessment is done by teams of engineers who manually review sensor data, performance data, and engine and component operating histories. Based on review of information from these various sources, an evaluation is made as to the health of each component of the SSME and the preparedness of the engine for another test or flight. The objective of this project - the SSME Post Test Diagnostic System (PTDS) - is to develop a computer program which automates the analysis of test data from the SSME in order to detect and diagnose anomalies. This report primarily covers work on the Systems Section of the PTDS, which automates the analyses performed by the systems/performance group at the Propulsion Branch of NASA Marshall Space Flight Center (MSFC). This group is responsible for assessing the overall health and performance of the engine, and detecting and diagnosing anomalies which involve multiple components (other groups are responsible for analyzing the behavior of specific components). The PTDS utilizes several advanced software technologies to perform its analyses. Raw test data is analyzed using signal processing routines which detect features in the data, such as spikes, shifts, peaks, and drifts. Component analyses are performed by expert systems, which use 'rules-of-thumb' obtained from interviews with the MSFC data analysts to detect and diagnose anomalies. The systems analysis is performed using case-based reasoning. Results of all analyses are stored in a relational database and displayed via an X-window-based graphical user interface which provides ranked lists of anomalies and observations by engine component, along with supporting data plots for each.

Description: Several methods for coupling the SP-100 space nuclear reactor to the NASA Lewis Research Center's Free Piston Stirling Power Convertor (FPSPC) are presented. A 25 kWe, dual opposed Stirling convertor configuration is used in these designs. The concepts use radiative coupling between the SP-100 lithium loop and the sodium heat pipe of the Stirling convertor to transfer the heat from the reactor to the convertor. Four separate configurations are presented. Masses for the four designs vary from 41 to 176 kgs. Each design's structure, heat transfer characteristics, and heat pipe performance are analytically modeled.

Description: The Optical Plume Anomaly Detection (OPAD) system is under development to predict engine anomalies and engine parameters of the Space Shuttle's Main Engine (SSME). The anomaly detection is based on abnormal metal concentrations in the optical spectrum of the rocket plume. Such abnormalities could be indicative of engine corrosion or other malfunctions. Here, we focus on the second task of the OPAD system, namely the prediction of engine parameters such as rated power level (RPL) and mixture ratio (MR). Because of the high dimensionality of the spectrum, we developed a linear algorithm to resolve the optical spectrum of the exhaust plume into a number of separate components, each with a different physical interpretation. These components are used to predict the metal concentrations and engine parameters for online support of ground-level testing of the SSME. Currently, these predictions are labor intensive and cannot be done online. We predict RPL using neural networks and give preliminary results.

Description: The experimental study on the fundamental processes involved in fuel decomposition and boundary-layer combustion in hybrid rocket motors is continuously being conducted at the High Pressure Combustion Laboratory of The Pennsylvania State University. This research will provide a useful engineering technology base in the development of hybrid rocket motors as well as a fundamental understanding of the complex processes involved in hybrid propulsion. A high-pressure, 2-D slab motor has been designed, manufactured, and utilized for conducting seven test firings using HTPB fuel processed at PSU. A total of 20 fuel slabs have been received from the Mcdonnell Douglas Aerospace Corporation. Ten of these fuel slabs contain an array of fine-wire thermocouples for measuring solid fuel surface and subsurface temperatures. Diagnostic instrumentation used in the test include high-frequency pressure transducers for measuring static and dynamic motor pressures and fine-wire thermocouples for measuring solid fuel surface and subsurface temperatures. The ultrasonic pulse-echo technique as well as a real-time x-ray radiography system have been used to obtain independent measurements of instantaneous solid fuel regression rates.

Description: Polyimide has been used extensively as the primary wiring insulation in commercial planes, military aircraft, and space vehicles due to its low weight, high service temperature, and good dielectric strength. New failure modes, however, have been associated with the use of polyimide because of the susceptibility of the insulation to pyrolization and arc tracking. A new wiring construction utilizing partially fluorinated polyimide insulation has been tested and compared with the standard military polyimide wire. Electrical properties which were investigated include AC corona inception and extinction voltages (sea level and 60,000 feet), time/current to smoke, and wire fusing time. The two constructions were also characterized in terms of their mechanical properties including abrasion resistance, dynamic cut through, and notch propagation. These test efforts and the results obtained are presented and discussed.

Description: A method for the mathematical analysis of linear alternator and linear motor devices and designs is described, and an example of its use is included. The technique seeks to surpass other methods of analysis by including more rigorous treatment of phenomena normally omitted or coarsely approximated such as eddy braking, non-linear material properties, and power losses generated within structures surrounding the device. The technique is broadly applicable to linear alternators and linear motors involving iron yoke structures and moving permanent magnets. The technique involves the application of Amperian current equivalents to the modeling of the moving permanent magnet components within a finite element formulation. The resulting steady state and transient mode field solutions can simultaneously account for the moving and static field sources within and around the device.

Description: This workshop addressed key technology issues in the field of electrical power wiring for space applications, and transferred information and technology related to space wiring for use in government and commercial applications. Speakers from space agencies, U.S. Federal labs, industry, and academia presented program overviews and discussed topics on arc tracking phenomena, advancements in insulation materials and constructions, and new wiring system topologies.

Description: Four tasks were completed in this period and results were published in AIAA papers. First, a Boltzmann-2D code, was developed and applied to compute MSFC-A2 nozzle/plume flow field. It solved the two-dimensional Boltzmann-BGK equation using the Finite Difference Discrete Ordinate (FDDO) numerical technique. The code was validated by experimental data for one-dimensional shock structure predictions, paper 95-2056. Successful results for nozzle/plume flow simulation using the developed Boltzmann-2D code were presented at the 1995 AIAA Aerospace Science Conference, paper 95-0627. Second, a computer code solving two-dimensional Burnett equations was developed and applied to low-density nozzle flow field calculation. Results were also published at the 1994 AIAA Thermophysics Conference, paper 94-2055. Third, the developed two-dimensional Burnett code was extended to compute axisymmetric flow field inside MSFC-A2 nozzle, paper 95-2008. The computed nozzle exit conditions are used as input data for Direct Simulation Monte Carlo (DSMC) plume calculation. Fourth, a DSMC code was modified to compute the exhausted plume near the nozzle exit and in the backflow region.

Description: Electrical power, as an area of study, is relatively young as compared to language, chemistry, physics, mathematics, philosophy, metallurgy, textiles, transportation, or farming. Practically all of the technology that has enabled the huge, continent-spanning power grids that have become ubiquitous in developed countries was developed in the last 150 years. In fact, Tesla's advocacy of alternating current for transmission just won out in the beginning of this century. Despite the novelty of the field as a whole, space power applications are, of course, much newer. This paper looks at the history of space power, and compares it to its older sibling on earth, forming a basis for determining appropriate transitions of technology from the terrestrial realm to space applications.

Description: This document contains results obtained in the process of performing a power system definition study of the TROPIX power management and distribution system (PMAD). Requirements derived from the PMADs interaction with other spacecraft systems are discussed first. Since the design is dependent on the performance of the photovoltaics, there is a comprehensive discussion of the appropriate models for cells and arrays. A trade study of the array operating voltage and its effect on array bus mass is also presented. A system architecture is developed which makes use of a combination of high efficiency switching power convertors and analog regulators. Mass and volume estimates are presented for all subsystems.

Description: As part of the NASA CSTI High Capacity Power Program on Conversion Systems for Nuclear Applications, Sunpower, Inc. completed for NASA Lewis a reference design of a single-cylinder free-piston Stirling engine that is optimized for the lifetimes and temperatures appropriate for space applications. The NASA effort is part of the overall SP-100 program which is a combined DOD/DOE/NASA project to develop nuclear power for space. Stirling engines have been identified as a growth option for SP-100 offering increased power output and lower system mass and radiator area. Superalloy materials are used in the 1050 K hot end of the engine; the engine temperature ratio is 2.0. The engine design features simplified heat exchangers with heat input by sodium heat pipes, hydrodynamic gas bearings, a permanent magnet linear alternator, and a dynamic balance system. The design shows an efficiency (including the alternator) of 29 percent and a specific mass of 5.7 kg/kW. This design also represents a significant step toward the 1300 K refractory Stirling engine which is another growth option of SP-100.

Description: The impacts of introducing liquid rocket booster engines (LRB) into the Space Transportation System (STS)/Kennedy Space Center (KSC) launch environment are identified and evaluated. Proposed ground systems configurations are presented along with a launch site requirements summary. Prelaunch processing scenarios are described and the required facility modifications and new facility requirements are analyzed. Flight vehicle design recommendations to enhance launch processing are discussed. Processing approaches to integrate LRB with existing STS launch operations are evaluated. The key features and significance of launch site transition to a new STS configuration in parallel with ongoing launch activities are enumerated. This volume is part two of the study products section of the five volume series.

Description: The impacts of introducing liquid rocket booster engines (LRB) into the Space Transportation System (STS)/Kennedy Space Center (KSC) launch environment are identified and evaluated. Proposed ground systems configurations are presented along with a launch site requirements summary. Prelaunch processing scenarios are described and the required facility modifications and new facility requirements are analyzed. Flight vehicle design recommendations to enhance launch processing are discussed. Processing approaches to integrate LRB with existing STS launch operations are evaluated. The key features and significance of launch site transition to a new STS configuration in parallel with ongoing launch activities are enumerated. This volume is the executive summary of the five volume series.

Description: Liquid rocket booster integration study is presented. Volume 4 contains materials presented at the MSFC/JSC/KSC Integrated Reviews and Working Group Sessions, and the Progress Reviews presented to the KSC Study Manager. The following subject areas are covered: initial impact assessment; conflicts with the on-going STS mission; access to the LRB at the PAD; the activation schedule; transition requirements; cost methodology; cost modelling approach; and initial life cycle cost.

Description: The impacts of introducing liquid rocket booster engines (LRB) into the Space Transportation System (STS)/Kennedy Space Center (KSC) launch environment are identified and evaluated. Proposed ground systems configurations are presented along with a launch site requirements summary. Prelaunch processing scenarios are described and the required facility modifications and new facility requirements are analyzed. Flight vehicle design recommendations to enhance launch processing are discussed. Processing approaches to integrate LRB with existing STS launch operations are evaluated. The key features and significance of launch site transition to a new STS configuration in parallel with ongoing launch activities are enumerated. This volume is part one of the study products section of the five volume series.

Description: The impacts of introducing liquid rocket booster engines (LRB) into the Space Transportation System (STS)/Kennedy Space Center (KSC) launch environment are identified and evaluated. Proposed ground systems configurations are presented along with a launch site requirements summary. Prelaunch processing scenarios are described and the required facility modifications and new facility requirements are analyzed. Flight vehicle design recommendations to enhance launch processing are discussed. Processing approaches to integrate LRB with existing STS launch operations are evaluated. The key features and significance of launch site transition to a new STS configuration in parallel with ongoing launch activities are enumerated. This volume is the appendices of the five volume series.

Description: The impacts of introducing liquid rocket booster engines (LRB) into the Space Transportation System (STS)/Kennedy Space Center (KSC) launch environment are identified and evaluated. Proposed ground systems configurations are presented along with a launch site requirements summary. Prelaunch processing scenarios are described and the required facility modifications and new facility requirements are analyzed. Flight vehicle design recommendations to enhance launch processing are discussed. Processing approaches to integrate LRB with existing STS launch operations are evaluated. The key features and significance of launch site transition to a new STS configuration in parallel with ongoing launch activities are enumerated. This volume is the study summary of the five volume series.

Description: The purpose of this paper is to describe the design of the Space Station Electrical Power System. This includes the Photovoltaic and Solar Dynamic Power Modules as well as the Power Management and Distribution System (PMAD). In addition, two programmatic options for developing the Electrical Power System will be presented. One approach is defined as the Enhanced Configuration and represents the results of the Phase B studies conducted by the NASA Lewis Research Center over the last two years. Another option, the Phased Program, represents a more measured approach to reaching about the same capability as the Enhanced Configuration.

Description: Recent developments and progress in indium phosphide solar cell research for space application are reviewed. Indium phosphide homojunction cells were fabricated in both the n+p and p+n configurations with total area efficiencies of 17.9 and 15.9% (air mass 0 and 25 C) respectively. Organometallic chemical vapor deposition, liquid phase epitaxy, ion implantation and diffusion techniques were employed in InP cell fabrication. A theoretical model of a radiation tolerant, high efficiency homojunction cell was developed. A realistically attainable AMO efficiency of 20.5% was calculated using this model with emitter and base doping of 6 x 10 to the 17th power and 5 x 10 the the 16th power/cu cm respectively. Cells of both configurations were irradiated with 1 MeV electrons and 37 MeV protons. For both proton and electron irradiation, the n+p cells are more radiation resistant at higher fluences than the p+n cells. The first flight module of four InP cells was assembled for the Living Plume Shield III satellite.

Description: The selection of a propulsion system for a man-tended platform has been influenced by the planned use of resistojets for drag make-up on the manned space station. For that application a resistojet has been designed that is capable of operation with a wide variety of propellants, including water. The reasons for the selection of water as the propellant and the performance of water as a propellant are discussed. The man-tended platform and its mission requirements are described.

Description: A study was conducted to assess the feasibility of quasi-hybrid solid rocket boosters for advanced Earth-to-orbit vehicles. Thermochemical calculations were conducted to determine the effect of liquid hydrogen addition, solids composition change plus liquid hydrogen addition, and the addition of an aluminum/liquid hydrogen slurry on the theoretical performance of a PBAN solid propellant rocket. The space shuttle solid rocket booster was used as a reference point. All three quasi-hybrid systems theoretically offer higher specific impulse when compared with the space shuttle solid rocket boosters. However, based on operational and safety considerations, the quasi-hybrid rocket is not a practical choice for near-term Earth-to-orbit booster applications. Safety and technology issues pertinent to quasi-hybrid rocket systems are discussed.

Description: The objective of this program is to develop generic load models to simulate the composite load spectra (CLS) that are induced in space propulsion system components representative of the space shuttle main engines (SSME). These models are being developed through describing individual component loads with an appropriate mix of deterministic and state-of-the-art probabilistic models that are related to key generic variables. Combinations of the individual loads are used to synthesize the composite loads spectra. A second approach for developing the composite loads spectra load model simulation, the option portion of the contract will develop coupled models which combine the individual load models. Statistically varying coefficients of the physical models will be used to obtain the composite load spectra.