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NASA HYDROGEN PEROXIDE PROPULSION PERSPECTIVERonald J. Unger

Lead Systems Engineer, On-Orbit Propulsion Systems2 dGeneration Reusable Launch Vehicle Program Office

NASA/Marshall Space Flight Center

Good morning, ladies and gentlemen. My nameis Ron Unger, and I am from the Marshall SpaceFlight Center. 1 serve as both the Lead SystemsEngineer for the On-Orbit Propulsion SystemsProject and the Lead Sub-System Manager forthe peroxide component development workunder the On-Orbit Project. You may be morefamiliar with the Upper Stages project termfrom previous meetings and contacts. Areorganization last spring brought the UpperStages peroxide work under the newly-formedOn-Orbit project.Overview

This presentation is to provide the current statusof NASA's efforts in the development ofhydrogen peroxide in both mono-propellant andbi-propellant applications, consistent with theSpace Launch Initiative goals of pursuing lowtoxicity and operationally simpler propellants tbrapplication in the architectures being consideredfor the 2 d Generation Reusable Launch Vehicle,also known as the Space Launch Initiative, orSLI.In 1997, NASA recognized the industry-widegreat void (CHART 1), a term my colleagueCurtis McNeal coined, which existed in thedevelopment and use of hydrogen peroxide inpropulsion systems. Traditional thinking in termsof environment, operations, and acceptablehazards had all been deeply entrenched duringthe period of the 'great void, in which timehydrazines and NTO were the de factopropellants of choice for long-term, ambienttemperature, on-orbit applications. But as part ofthe realization of the peroxide technology voidcame the revelation that peroxide also hadpossibilities as an on-orbit propellant, and withits low-toxicity nature, could provide operationaland environmental benefits not available with theuse of hydrazine mono-propellant and bi-propellant systems. Starting then in the 1997time frame (CHART 2), solicitations andcontract awards begun under the NRA8-19 andNRA8-21 procurement vehicles were initiated, tobring peroxide back into a level of legitimateconsideration for upper stage and on-orbit

applications. This work was seen as potentiallyvaluable and applicable to the goals of SLI, thusthe work was scooped up administratively and isnow managed as part of the SLI Program.Since this conference last convened, NASA hassponsored a number of risk reduction activities or the purpose of advancing the understandingof peroxide's advantages and disadvantages thatthe SLI architecture contractors should considerwhen conducting propellant trade studies for the2 d Generation Reusable Launch vehicle. Muchof the data on the completed work are availableto the US peroxide community. A number ofactivities are also ongoing, and will continue intothe next calendar year.Component DevelopmentI would like to first address some of thehardware concepts that have been underdevelopment by way of NASA sponsorship.Within the context of the SLI initiated contracts,as well as some pre-SLI awards, Marshall hasbeen managing a number of successful peroxidecomponent development efforts consistent withthe long-life and reliability goals of SLI.In late 2001, through a cooperative agreementwith the Boeing Company, we have successfullycompleted the development of a long-lifecatalyst/gas generator system (CHART 3).Various diameter catalyst beds were tested, alongwith a wide range of test parameters, such as bedloading, chamber pressure, and start conditions.The final design of the catbed and chamber hasproven to be rugged and reliable, with noapparent degradation of the hardware and nochamber pressure roughness developing at theend of a long-life test series. The system hasapplications for powering turbopumps as well asbeing a hot gas source for an advancedperoxide/hydrocarbon ignition system.As a follow-on to the development of theadvanced gas generator, Boeing proceeded earlythis year to demonstrate the operation of itsadvanced ignition system (CHART 4). The

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igniter utilizes hot decomposed hydrogenperoxide as an ignition and oxidizer sourcewithin the torch igniter to raise the injectedhydrocarbon fuel above its autoignitiontemperature. Various mixture ratios and flowrates demonstrated the robust design, both inigniter-only and integrated igniter tests. In thesetests, the igniter was used to ignite a maininjector and chamber assembly using the samefuels as the igniter, thus supporting the approachof having fewer and safer fuel storagerequirements for a flight vehicle. The torchigniter demonstrated reliable ignition,survivability in its thermal environment, andstable operation.Currently under development (CHART 5), andscheduled for testing before the end of this yearat Stennis Space Center is Boeing's advancedperoxide turbopump. Again utilizing theadvanced gas generator, this time to power theturbine, we plan on performing a number of testsdemonstrating the throttleability and robustnessof this design for peroxide/hydrocarbonapplications. The hardware fabrication is nearingcompletion, and delivery to Stennis is expectedvery soon. Concurrent with the hardwarefabrication is the general peroxide upgrade effortat Stennis in the E3 test complex which willaccommodate the turbopump testing in Cell 1, aswell as the hypergolic injector tests, to beconducted in Cell 2. I will discuss more aboutthe injector later. To help expedite the facilitypreparation process for the turbopump testing,we have had a stereolithography model built ofthe turbopump (as shown in the chartt, thismodel has allowed fit checks with the testhardware and running of test article feed linesprior to the actual delivery of the turbopump.This approach helped mitigate some criticalschedule concerns for turbopump delivery, aswell as minimize the exposure of the actualturbopump to construction and contaminationhazards.

Another component effort underway is thedevelopment and test of a hypergolic injector(CHART 6). In diverting from the advancedigniter concept previously discussed whichutilized an independent catalytic/hot gas ignitionsystem, this injector concept utilizes ahydrocarbon fuel to which is added a Boeing-proprietary chemical mixture which igniteshypergolically with peroxide. The potentialbenefits are substantial - performance of thishypergolic injector is expected to be very near

the peroxide/hydrocarbon combination, thepropellants are of low-toxicity, and no separateignition system is required. As with theturbopump, a stereolithography model is beingprepared to expedite facility interface and fitchecks. The injector hardware, with two distinctrisk-reduction configurations, is nearing itsdelivery date to Stennis, also to be tested laterthis year in the E3 Cell 2 position.These aforementioned components are allcomparably sized for an engine systemapplication, which would fit the expectedrequirements of an upper stage or OrbitalManeuvering System engine, if selected for usein an SLI architecture.

Propellant Studies

I would like to now switch to the propellantstudies being sponsored by Marshall.Marshall has several activities which either werecompleted this past year or are on-going both in-house as well as contracted. These studies areintended to further the understanding of theeffects of manufacturing processes and purity ofperoxide on catalyst beds and the fluid physics ofperoxide in an on-orbit application. Additionally,we are looking at the hypergolic nature of thecombination of peroxide with theaforementioned blended hydrocarbon fuel.Completed last winter was a contract withGeneral Kinetics (CHART 7) to study the effectsof peroxide processing impurities and stabilizersas well as the effects of rapid pulsing (as in athruster pulse mode) on the catalyst performanceand life. The impurity study resulted in a newdraft procurement specification (well withinexisting manufacturing process capabilities) forrocket-grade hydrogen peroxide, while the pulsetesting showed that catalysts can hold up underrepresentative thermal cycles in thrusterapplications with no apparent degradation. Thisrisk-reduction effort was significant towardsproviding alternative architecture options overother traditional storable or LOX/ethanol thrustersystems.Two grants were awarded to Purdue Universitythis past spring (CHART 8). The first actuallyhas two distinct tasks: the study of the thermaldecomposition and vaporization phenomena ofperoxide injected into a flow field of peroxidedecomposition products, and the vacuum ignition

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characterization of peroxide and the Boeinghypergolic blend. In a paper previouslydiscussed at this conference, efforts are alreadyunderway to study and report on the phenomenaof decomposition and vaporization. Marshall'sfunding will allow further investigation as wellas the creation of a refined model describing thephenomena. The Marshall task will result in thedevelopment of a design database useful foroptimizing catbed sizes, decompositionchambers, combustors, and staged combustionflow ratios, as well as increasing theunderstanding of the potential for combustioninstability.We are also proceeding in the planning anddesign of a vacuum chamber and injector to testthe vacuum ignition characteristics of peroxidewith the Boeing hypergolic blend at bothreduced ignition pressures and varyingpercentages of the propellant blend constituents,which will also support the yet-to-be discussedfuel optimization tests being conducted atMarshall.

The second grant (CHART 9) that we have withPurdue is to perform a demonstration of atraditional surface tension PropellantManagement Device configuration usingperoxide-compatible materials. Thedemonstration will be conducted in Purdue'sdrop tower to provide for an actual zero-genvironment in order to visually verify thewicking process of peroxide within the PMD.(CHART 10) In support of Boeing's hypergolicinjector development, Marshall has an in-housefuel optimization program on-going, facilitatedby a license agreement between Boeing andNASA for the use and development of this fuelfor SLI. We are currently in the midst of aprogram to test certain characteristics based onthe specific percentages of constituents withinthe fuel to establish the optimum blend.Parameters such as ignition delay, corrosion,lubricity, cost, specific impulse, and others arebeing tested to help establish the optimum blend.Ignition delay tests have been completed, andlubricity testing is underway. As previouslymentioned, Purdue will conduct the hot-firespecific impulse performance testing.

Material Compatibility StudiesNow to our last major area of activity. Marshallhas either completed or has several on-goingactivit ies in material compatibili ty.

Last winter we concluded an effort with Prattand Whitney (CHART 11) to study detonabilityand operating limits when using peroxide as acoolant in a combustion chamber wall. The studyconsidered such factors as coolant channel size,heat flux, material compatibility, channel surfaceroughness, peroxide flow velocity, and flowpressure. This parametric study will contribute toa design methodology which precludes thedecomposition and/or detonation of peroxidewhen used as a chamber wall coolant.

In an effort (CHART 12) more strictly in linewith the testing of material compatibility andheat flux efficiency at the peroxide/chamber wallinterface, Marshall has Boeing under contract toperform an extensive investigation anddownselect of candidate main combustionchamber materials. The study has looked initiallyat such parameters as channel wall and tube wallconstruction for thermal management boundaryconditions and structural issues, initialcompatibility of the material system assessed viahigh-temperature immersion testing, bondingsystems and passivation techniques. As part ofthis effort, we have completed a critical designreview for a materials compatibility test fixture,along with receiving the recommendations of thefour materials to be continued into the testingphase. Presently, the continuation of thefabrication of the test fixture and actual testing ofthe materials has been put on hold until later inFiscal Year 03.Concurrent with the test fixture design process,Marshall began support to the effort by initiatingmicrocatorimetry testing on the final fourdownselected materials, exposing the materialspecimens to 98 peroxide and measuring theheat generated during decomposition as well asthe rate of change of peroxide concentration.This testing is scheduled to for completion thismonth.Conclusion

In summary, I have described the activities thatMarshall has sponsored over this past year, butthe original context of this talk was to be on aNASA peroxide perspective. Please keep in

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mind that the driver for the activities described isto ultimately support the 2 ''d Generation vehiclearchitecture decisions. There are competingupper stage, OMS, and thruster concepts beingdeveloped and/or evaluated, such asLOX/ethanol, that are vying for selection forinclusion in the architectures. Marshall isfacilitating this evaluation by providing fundingfor development of these less-than-matureconcepts to help reduce the risks as they areconsidered in the architecture trade studies.Thus, Marshall is not mandating which of thesetechnologies to incorporate in any givenarchitecture. Theretbre, our perspective is one ofopen-minded consideration for all potentialpropellant candidates that meet the over-archinggoals of the SLI program of safety and cost.Also, without doubt, you have questions as tohow well peroxide is standing up againstcompeting concepts as the architectures develop.The pending architecture downselects, whichwill be contractor proprietary, as well as theupcoming cycle II contract awards prevent mefrom addressing any specifics.I would like to thank John Rusek and BillAnderson for inviting me to present this NASAperspective. I appreciate your attention and wishyou an enjoyable last day at the Conference.

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_ SPACELAUNCHINITIATIVE

Broadresearch inperoxidepropulsionunderway,Includinghybrids, 90and 98peroxide

1960s

MercuryH=Oz RCSAR2-3

fielded forUSAFStentorfielded byBritish NavyBritish

launch onesate ll ite onBlack KnightNASA X-15H=O2 ACS

I ' I -I 1990sLittle/no activity

Y

No fluid suppliersNo component supp ers

No infrastructureNo industry experience base

No customers

Chart 1

Peroxide Propulsion Development1997-2002 SL]A SPACE LAUNCH INITIATIVE

I I - I .. I _1 _ II USFE engine tests at SSC J

I USFE subscale tank program J

No Fluid SuppliersNo componentsuppliers

No infrastructureNo industry

experience baseNO customers

I AR2-3 engine tests at SSC JiI NASA initiates Upper Stages project now On-Orbit project)

I Peroxide Enrichment Skid

I CatalysUGG Development JI Igniter Development JI Turbopump development IPeroxide Hybrid development I

Chart 2

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Gas Generator DevelopmentS PA CE L AU NCH I NI TI AT IVE

Chart 3

Advanced Igniter DevelopmentSPACE LAUNCH INITIATIVE

Chart 4

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DRAFT@ Advanced Hydrogen Peroxide/Hydrocarbon Turbopump Av SP ACE LA UNC H I NI TI AT IVEF

Chart 5@ Hypergolic Injector A SP ACE LA UNCH I NI TI AT IVE

Stereolithography modelparts to be used for facilityinterface checks

Chart 6

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A

I

SPACE LAUNCH I NITIATI VE

Test set up forcatalyst sensitivityand pulse testing

Chart 7

Thermal Decomposition/Vaporization andHypergolic Ignition Studies -_ _S PA CE LA UN CH I NI TI AT IVE

Synchronizedstroboscope|

Hot gasgenerator

,_/ PropellantAerodynamic

drop generatorTelescopicCCD camera

PC DACS

Valves

BurstDisk

Will characterize the vaporization and shatteringof peroxide droplets and allow creation ofindustry model which can be used in rocketcomponent design using peroxide, such asinjectors, catalysts, combustion chambers, etc.

Chart 8

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S PAC E LA UNC H I NI TI AT IV E

Device Demonstration

Example of zero gravity wickingeffects in Purdue drop tower

A

Chart 9

Hydrogen Peroxide/Hypergolic Fuel Optimization

SPA CE L AU NCH I NI TI AT IVE

High speed vi eo eing used todetermine ignition rate of

hypergolic blend with peroxideOptimum combinationChart 10

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Hydrogen Peroxide Detonation Study __S PA CE L AU NCH I NI TI AT IVE

Test apparatus simulatesa rocket engine chambercooling passage

iChart 11

Main Combustion Chamber t_-_..Materials Compatibility_ Study___4 _ _

S PA CE LA UN CH I NI TI AT IVE

Microcalorimetry tests arenearing conclusion on fourcandidate main combustion

chamber materials

Chart 12