TOPIC A4 Next Generation Launch Technologies

• Innovated analysis tools, and testing techniques applicable to assessment of credible physics associated with NGLT thermal protection system designs, compartment thermal control requirements, cryotank thermal characteristics, and vehicle base heat shield requirements.
  
• Control and health management of vehicle structural systems by using sensors that have little influence on the structural parameters with the exception of the structural damping parameters. Innovative vehicle preliminary design tools that support the design, analysis, and integration of vehicle systems and propulsions subsystems (such as the ability to assess operability of the overall launch vehicle concept and to model the impacts of design changes on vehicle cost, operations, crew safety, vehicle aerodynamics, and controllability). These tools would significantly enhance the overall systems engineering evaluation of potential reusable launch vehicle architectures.
  
• Integrated CAD, solid-model, structural, dynamic, thermal, and fluid-flow analysis methods for multidisciplinary analysis and optimization of subsystems, components, and overall launch vehicle systems; and improved vehicle analysis tools in the areas of stress, thermal, structures, fluid dynamics, and acoustics.
  
• Manufacturing and testing techniques that will allow for significant reduction in the cost and schedule required for wind tunnel aerodynamic testing of candidate NGLT configurations.
  
• Innovative analysis techniques to assess propellant management systems, feed lines, tank pressurization, fill, drain, and vent requirements.
  
• Methodologies and analysis tools for investigation and assessment of optimal fault detection and redundancy management strategies; execution software and advanced navigation hardware/software architectures; adaptive GN&C utilizing data from sensors such as GPS; guidance concepts that will reduce operational costs and increase reliability by autonomously reshaping trajectories and retargeting landing sites in the presence of abort/failure situations to satisfy vehicle and control constraints to achieve a safe abort.
  
• Methodologies and analysis tools for investigation and assessment of advanced control concepts that will reduce operational costs and increase reliability by adapting to changing missions/payloads/vehicle models/failures and abort scenarios without requiring ground effort to retune.
  
• Methodologies and analysis tools for investigation and assessment of automated mission planning techniques for planning flight operations of NGLT vehicles, including trajectory planning, launch window and timeline determination, generation of initialization loads, and verification that the GN&C will successfully fly the vehicle.
  
• Analysis and testing techniques for assessment of damage and stress including life cycle predictions, progressive internal damage and dynamic response in structures containing ceramic-matrix, metal-matrix composites, or other composite materials; and nondestructive evaluation of structural integrity of vehicle subsystem and component materials. Methods for efficient characterization of frequency response functions of large structures, and analysis and testing techniques for passive and active vibration isolation devices for launch vehicles and payloads.
  
• Innovative microwave nondestructive evaluation (NDE) techniques to assess flaws and the integrity of thermal protection system materials.
  
• Advanced methods and tools for prediction and assessment of unsteady environments applicable to reusable launch vehicle systems and components. Methods to predict and evaluate the internal fluctuating environments of propellant delivery systems, dynamic contributions of cavitating pumps, and vehicle/engine system dynamic stability. Methods to predict and evaluate steady and unsteady external environments of complex vehicle/engine combinations relating to geometrically complex external aerodynamics, engine start/launch overpressures, and noise related to flow dynamics.
  
• Advanced methodologies for thermal and structural assessment of large integrated composite cryogenic tanks, assessment of efficient and effective tank repair techniques, and technologies associated with modal, acoustic and static testing of large-scale aerospace structural systems.
  
• Innovative experimental-empirical methods for composite material thermal characterization and response prediction.
  

• Development of an environmentally durable fiber-reinforced refractory composite materials and their components,
  
• Actively cooled, CMC flow path components which contain pressure,
  
• Development of turbomachinery with inserted CMC blades,
  
• Development of the means to contain pressure and account for movement due to thermal growth and operation of connecting systems in uncooled CMC piping,
  
• Development of functionally formed components; CMCs with optimal and hybrid fiber tows and architectures, interface coating systems, inhibitors, matrices (e.g., glass/ceramic), and environmental barrier coatings which best suits function of the component for a specific portion of the component (e.g., CMC face sheet with PMC backing, high-conductivity material transitioned to low-conductivity material in the same component, embedded CMC thrust chambers in a flow path, integral injector and cooled chamber, etc),
  
• Sealing and/or joining of CMCs to metals and ceramics for cooled components, manifolding, inserted blades, and end user-specified components accounting for fiber directions, surface conditions of the materials to be seal/joined, system loads and environments, and potential interactions between the materials to be sealed/joined (both during processing and subsequent use),
  
• Low-cost (with metrics), rapid, scalable, repeatable CMC fabrication process development for the preceding applications. Clearly state how the process quality will be measured and validated from batch to batch or with respect to time. Note any limitations.
  

• Explanation of how aspects of similar, previous efforts are leveraged.
  
• Identification and explanation of key issues and how they are mitigated within the technology developed.
  
• Explanation of how the technology developed will address key issues and mitigate risks for targeted/candidate propulsion systems with respect to NASA goals.
  
• Identification of path to prove assessment and accountability of the technology product with respect to their value toward reaching NASA's goals.
  
• Identification of potential end users that would integrate the technology product(s) into a propulsion system.
  
• Listing of all deliverables. When components or systems are delivered to NASA for potential testing and analyses, plans for manifolding (for cooling and gas ducting), attachment and hardware assembly, and technology integration are sought. Desired deliverables include: Components, test data, and material analyses as appropriate, hoop or flat tensile stress-strain curves, interlaminar shear, and other coupon test data, microscopic analysis images, edge-loaded tensile specimens (maximum of nine).
  
• Justification for selection of matrix material constituents, fibers, interface coatings, fabric architecture, etc.
  
• For process development, inclusion of a flexible, process-development matrix (e.g., which variables changed and how many processing trials) and ideally a Design of Experiments.
  
• Correlation of processing variables to flexible, detailed test matrices (include in reports also).
  
• Verification of processes with microscopic analysis (e.g., microprobe, SEM, XRD, TEM, etc.) and macroscopic analysis (e.g., tensile strength, stress-oxidation, thermal mechanical fatigue, interlaminar shear strength, thermal and physical properties, etc.).
  
• Verification of specific end-use application by testing for permeability, thermal shock, etc.
  
• Evaluation of components and/or coupon material using nondestructive characterization techniques.
  
• Explanation of manufacturing scale-up necessary for the ultimate full-size target components.
  

• Specialized modeling, analysis, and design tools for integrated aerothermal, thermal, thermal-structural responses. Innovative measurement and test methods for design validation. Application of methodology to hot aerosurfaces, and to integrated thermal-structural concepts for tanks is of special interest.
  
• Novel methods for prediction and testing of material and structural durability and damage tolerance, with emphasis on environmental degradation, combined thermal-mechanical loads, and operation beyond nominal design conditions; and related methods to repair damaged structures.
  

• Significant advances in critical properties for high-temperature materials such as nickel, iron, and titanium alloys, intermetallics, refractory metals, MMC’s, and CMC’s along with their related processing into useful product forms for fabrication into the airframe systems of interest.
  
• Materials technologies focused on advanced, high-temperature materials compatible with cryogenic and gaseous hydrogen and oxygen, and high-temperature products of combustions such as water vapor.
  

• New, innovative non-intrusive sensors for measuring flow rate, temperature, pressure, rocket plume constituents, and detection of effluent gas. Sensors must not physically intrude at all into the measurement space. Sub millisecond response time is required. Temperature sensors must be able to measure cryogenic temperatures of fluids (as low as 160R for LOX and 34R for LH2 ) under high pressure (up to 15,000 psi) and high flow rate conditions (2000 lb/sec, 300 ft/sec) for LH2. Pressure sensors must have a range of up to 15,000 psi. Rocket plume sensors must determine gas species, temperature, and velocity for H2 , O2 , hydrocarbons (kerosene), and hybrid fuels.
  
• On-line (real-time) sampling and analysis of high-pressure, high flow rate liquid oxygen-nitrogen mixtures. There is a significant need for real-time, totally non-intrusive instrumentation for high-pressure, high flow rate liquid oxygen (LOX) systems, having the capability to detect the presence of other chemical species present in the LOX, which may have been introduced through the pressurization process. An example would be the detection of N2 in a LOX flow, where N2 is used to pressurize the LOX delivery system. The technology should be expandable to include other rocket engine propellants.
  
• On-line particulate contamination sampling for facility propellant (LOX and LH2 ) and gas systems (He, H2 , O2 , and N2 ). A requirement exists for instrumentation that can detect, in real time, the presence of contaminants in the 30 micron to 100 micron range as these propellants and gases flow through facility piping. Sub millisecond response time and ability to withstand cryogenic temperatures (down to 34R) and high pressures (up to 15,000 psi) are required features.
  
• Miniature front-end electronics to support embedding of intelligent functions on sensors. Requirements include computational power comparable to a 200 MHz PC with 32 MB of RAM or similar nonvolatile storage, analog I/O (at least two of each, with programmable amplification, anti-aliasing filters, and automatic calibration), digital I/O (at least eight), communication port for Ethernet bus protocol (one high speed and one low speed), support for C programming (or other high-level language), and development kit for PC. Physical size should not occupy a volume larger than 4" x 4" x 2".
  
• Modeling of the high temperature rocket engine plume radiance and transmittance. Modification of MODTRAN code to include HITEMP database and to include radiance emanating from the engine and the test stand structural materials at high temperatures. Modeling of the engine plume water vapor condensation clouds hovering over and near the test stands. All these effects are required in order to predict radiance effects of the rocket engine testing accurately.
  
• Methods and instrumentation for rocket plume spectral signature measurements. There are requirements to develop enhanced capabilities in the area of rocket exhaust plume spectral signature measurements. Emphasis is on developing data acquisition, analysis, display software, and systems to support infrared spectrometers, imaging systems, and filter radiometer systems. Overall system concepts should include instrument system calibration methodologies and data uncertainty analysis.
  
• Materials and components for high-pressure (up to 6000 psi), high-purity (90%+) hydrogen peroxide service. Materials, including seals, valve materials, and coatings that can withstand long-term hydrogen peroxide contact are required. Components for hydrogen peroxide service, including isolation valves, ball valves, and relief valves, which are designed for minimum number of sumps and seals, and clean flush-through, are required.
  
• Measurements and data are the product of ground testing. High accuracy, precision, uncertainty bands, and error bands are important elements of the data which is generated, and this must be quantified. Techniques and models to determine these parameters for active test facilities are required.
  

• Innovative technologies, design and analysis tools applicable to assessment of credible physics associated with reusable launch vehicle turbomachinery, combustion devices, and overall engine systems concepts. Design and analysis tools that provide improved understanding and quantification of component, subsystem, and system operating environments are of particular interest.
  
• Development of fluid/structural interaction simulation tool for assessment of (1) Transient loads in nonlinear valve/actuator hardware, (2) Cracking in engine ducts and flow liners, (3) Dynamic loads on component sensors, (4) Cavitation in engine components, (5) Sloshing in fuel tanks, and others. Complex fluid/structure interaction problems generally entail turbulent flows, complex geometries and/or transient conditions, and disregarding fluid/structure interaction may result in performance degradation or failure. Therefore, the overall objective is to develop a simulation approach to solve such problems with reduced computational time and improved capability. Related objectives include (a) effective finite element analysis for truly multidisciplinary response analysis of engine and vehicle components; (b) innovative use of high-performance computers, including parallel processing, for integrated systems analysis and multidisciplinary structural response analysis; (c) innovative applications of high-performance computer graphics for visualizing computer models and results; and (d) validation of multidisciplinary structural response modeling with test data, such as engine test fire and vibration data.
  
• Innovative propulsion system and component preliminary design tools that support the design, analysis, and integration of propulsion subsystems. These tools should significantly enhance the overall systems engineering evaluation of potential reusable launch vehicle concepts such as tools for component/parameter sensitivity analysis, quantification of system benefits to changes, the operability of the overall propulsion system concept, bottoms-up weight estimating, cost estimating, and reliability prediction of propulsion systems.
  
• Innovative turbomachinery and combustion devices concepts that address fundamental issues such as bearing and turbine blade life, combustion chamber cooling, injector design, sealing, increased thrust to weight ratio, and design features that facilitate manufacturing.
  
• Manufacturing techniques that will allow for significant reduction in the cost and schedule required to fabricate engine and main propulsion system components for candidate RLV concepts.
  
• Innovative analysis techniques to assess propellant management systems, feed lines, tank pressurization, fill, drain, and vent requirements.
  
• Innovative concepts for solid or hybrid rockets that increase mass fraction and decrease the need for thermal insulation and reduce or eliminate the need for staging. Concepts that drastically reduce the required launch complex preparation with the goal of providing a cost-effective launch-on-demand system for spacecraft.
  
• Innovative approaches using current or emerging processes and manufacturing technologies to design and develop valves, actuators, ducts, lines, flanges, seals, gimbal joints, bellows, and ancillary components that will reduce complexity and increase reliability, and are easier to assemble, install and test when integrated onto the vehicle.
  
• Integrated Computer aided design, solid-model, structural, dynamic, and thermal & fluid-flow analysis methods for multidisciplinary analysis and optimization of components and subsystems.
  
• Innovative materials and coatings for more robust valve designs, leading to increased life and extended durability and wear properties.
  
• Innovative manufacturing and testing techniques that will allow for significant reduction in the cost and schedule required to perform subsystem and component development.
  
• Utilization of advanced materials to reduce weight and tailor properties such as stiffness for valves, actuators, gimbal joints, ducts and lines.
  
• Innovative valve seal designs contributing to increased life, reliability, wear, material compatibility and decreased leak rates, friction and cost.
  
• Valve health monitoring systems and sensor technology which can record, store, and download performance data for monitoring, predicting and trending key parameters such as leak rate, torque, cycles, etc., from ground checkout through flight.
  
• New and innovative analysis tools or techniques for determining pressure drops and flowrates throughout a gelled propellant feed system. Tools or techniques that can be incorporated into existing analysis or design tools are of particular interest.
  
• New and innovative designs for pumping gelled propellants to high pressures (>1000 psi). Emphasis is placed on designs that can be adapted for in-space applications.
  

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