Des Ign of Multi-Mission Chemical Propulsion Modules for Planetary Orbiters
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,-/ 7 0 26085-6001 -TUOO DES IGN OF MULTI-MISSION CHEMICAL PROPULSION MODULES FOR PLANETARY ORBITERS VOLUME ii: TECHNICAL REPORT 15 AUGUST 1975 Prepared for NASA AMES RESEARCH CENTER ; , under Contract NAS2-8370 (NASA-CR-137790): DESIGN OFIMULTI-ISSION N76-14197 CHEMICAL PROPULSION MODULES FOR PLANETARY 'ORBITERS, VOLUME 2: TECHNICAL REPORT (TRW ;Systems Group) 270 p HC $9.00 CSCL 21H Unclas G3/20 07169 26085-6001 -TUOO DESIGN OF MULTI -MISS ION CHEMICAL- PROPULSION MODULES FOR PLANETARY ORBITERS VOLUME II: TECHNICAL REPORT 15 AUGUST 1975 Prepared for NASA AMES RESEARCH CENTER under 'Contract NAS2-8370 The final report of this study is presented in three volumes: I Summary Report II Technical Report Ii Appendixes Use of Metric and English Units in this Report The results of this study are reported in metric and- English units. ' The metric notation generally is quoted first. However, since in the present transition phase most of the engineering work is still being performed in terms of English units, some of the supporting calcula tions are repoited only in these units. In other instances English units are stated first, with metric units in parentheses, e.g., in reference to a iZ-foot (3. 66-rineter) antenna dish. ii CONTENTS Page 1. INTRODUCTION AND SCOPY; OF STUDY L-1 1.1 Background 1-1 1. 2 Mission Constraints and Performance 1-2 Requ.i rer:ents 1.3 Missions to be Performed by the 1 -3 Multi-Mission Pro:ulsion Mlodules 114 Study Objectives I-, 1. 5 Relation to Previous and Concurrent Studies 1 -5 1.6 Organization of Report 1 -6 2. MISSION C.ASSE.S AND PROPULSION 2-1 REQUIREaM.INTS 2. 1 S-oeciticd Mission Set 2-1 2.2 Summary of M'ission Profiles 2-2 2.2. 1 Mercury Orbiter 2-2 2. 2. 2 Strn Orbiter 2-5 Z. Z. 3 Uranus Orbit Mission 2-7 2.2.4 Come' RTndezvous 'issions 2-9 Z.3 Summary of Maneuver Requirements Z-10 2.4 Applicability of Corninor. Propulsion Module Z-13 2.5 Payload Spacecraft Classes 2-15 3. PERFOIR.MANCE ANALYSIS 3-1 3. 1 Liunc Vehicle Performance 3-1 3.1. 1 Diversity of Shuttle Upper Stages 3-1 3. 1. 2 Pcrforrnranc Evaluation .3 3. 1. 3 "-)erformance Characteristics of Launch 3-4 Vehicle Candid.Ltes 3. Z Approach to 9Propu'sion Module Sizing 3-l 3.3 Lnitial Scaling Relations for Propulsion 3-8 Modute Inert Weight ;ii CONTENTS (Continued) Page 3.4 Orbit LIsertion Performance at Mercury 3-13 3.4. i'-. Thrust Orientation Mode 3-13 3..4. 2 'Effect of Thrust Level ,(Preliminary) 3-14 3. 5 Use of Piopulsion Module for Launch-Energy 3-15 Augmentation (Preliminary) 4. PROPUL8ION MODULE CONFIGURATION 4-I 4. i Configuration Guidelines and Constraints 4-1 4.2 Design Approach 4-3 4.2. 1 Propulsion Module Sizing 4-4 4.2.2 Mass Properties Control 4-4 4. 2. 3 Thrust-Level Considerations 4-7 4.2.4 Thermal Control Design Approach 4-10 4.2. 5 Structural Design Approach 4-1Z 4.2. 6 Retention of Propulsion Module at 4-16' Destination 4. Z. 7 Auxiliary Propulsion Functions 4-19 4.3 Propulsion Module Design Evolution and 4-2i Selection Rationale 4.3. 1 Propellant Tank Configurations 4-23 4.3. 2 Structural Concepts Alternatives 4-Z6 4. 3.:3 Kick Stage. Support. Structure 4-28 4.3.4 Summary of Preferred Design Rationale 4-28 4.4 Selected Design for Module A 4-30 (Spin-Stabilized Payload) 4.4. 1 Configuration for Mtercury Orbiter 4-30 4.4.2 Propellant and Pressurant Tanks 4-32 4.4.3 Sun Shade Design and Operation 4-33 4.4.4 Module A Configuration for Outer- A-36 Planet'Orbiters 4.4. 5 Mass Properties of Module A 4-40 4.4.6 Arrangement of Auxiliary Propulsion 4-44 iv CONTENTS (Continued) Page 4. 5 Selected De;sign for Module B.(Threc-Axis 4-47 Stabi';zec' Spacecraft) 4. 5. 1 Configuration -*or Mercury Orbiter 4-47 4. 5. "ProPellantand Pressurant Tanks 4 -48 4. 5. 3 Sun Shade Design .-50 4.5.4 Other Heat Shields 4-52 4. 5.5 Module B Configuration for Outer- 4-52 Planet Orbiters 4. 5.6 Mass Properties of Module B ,t-54 4. 5. 7 Arrangemnent and Use of Auxiliary 4-56 Propu~sio:n Thrusters 4.6 Deployment and Operating Modes 4--7 4.6. 1 Module A Inbound Mission 4-57 4.6.2_ Module A Outbound Missions 4-66 4.6.3 Module R Inbound Mission 4-69 4.6.4 Module B Outbound Missions 4-75 4.6. 5 Dvna:nics and Attitude Control 4-77 of Module B 4.7 Payload Spacecraft Modifications and .1-84 Interface Recuirements I.7. 1 Spacecraft Modifications of Pioneer 4-84 Class Spacecraft 4. 7. 2 Modifications of Mariner Class 4-86 Spacecraft 4. 7. 3 Design and Configuration Changes 4-87 Affecting All Payloads 4.8 Accommodation on Shuttle Orbiter 4 -S 4.8. 1 Conformance wit!h Cargo Bay l)im rsici'n 4-, 4.8.2 Structural Interface.i 4-89 4. 8. 3 Shiuttle Safety Im.plcations A4-9 4.8.4 Shutt!e/Propulsion Mxodule intertact: Provision~s 4. 9 Propulsion Modue V/eight Summary -98 v CONTENTS (Continued) Page 5. PROPULSION SYSTEM DESIGN 5-1 5. 1 Design Approach, System Considerations, 5-i and Tradeoffs 5. Z System Description 5-3 5.3 Propellant Storage and Acquisition 5-8 5.3. 1 Tankage Requirements and Materials 5-8 5.3.2 Propellant Acquisition 5-1i0 5.3.3 Propellant Tankage Configuration - 5-i1 Spinner 5.3.4 Propellant Tankage Configuration - 5-11 Three-Axis Stabilized System 5.3.5 Redundant Tank Wall for Oxidizers 5"-iZ 5.3.6 Propellant Storage Thermal Effects 5-iZ 5.3.7 Tank Size and Mixture Ratio 5-13 5.4 Pressurization Subsystem 5-13 5.5 Engine Design 5-15 5.5. 1 Design Considerations 5-i5 5.5.2 Selection of F IN H4 Engine Thrust 5-7 5.5.3 Chamber Pressure Selection 5-20 5.5.4 Area Ratio Selection 5-23 6. ENVIRONMENTAL PROTECTION AND RELIABILITY 6-i 6.1 Thermal Environment 6-1 6. 1. 1 Mercury Thermal Radiation 6-i 6. Z Thermal Control Approach 6-4 6.2.1 Thermal Design Concept 6-4 6. 2. Z Short-Term Sun Exposure of 6-7 Fluorine Tanks 6.2.3 Analysis of Sun-Shade Sizing Requirement 6-8 6.2.4 Fluorine Tank Thermal Control by 6-9 Heat Pipes vi CONI EN'FS (Co'inued) Page 6. 3 Microieteoroid KIEniro:.nt,:,t 6-I1 6.3. 1 Particle Inpact Rates for 6-1Z . ela:ettry Orbiters 6.3.2 Particle Fl:x Near Comets 6-15 6.4 Micrornetcoroid Protection Approach 6-15 6.5 Reliability 6-16 6. 5. 1 Reliability Criteria 6-16 6.5.2 Proplsion Module Design for Long-lie 6-21 Reliability 6. 5. 3 Areas for Further Study and Research 6-25 Related to Re!iability 7. SYSTEM PH:r.RMANC?: ASSk.SSMNT . 7-1 7. 1 Initial Per formiance ,.stimates and Performance 7-1 Improvement Options 7.2 Update(. nert Weight Estimates 7-Z 7.3 Mercury Orbiter Performance 7-4 7.4 Performance Comparison of Farth-Storable 7-4 and Space -Storable Systems in Outer Planet Missions 7.4. 1 Propellant Mass 7-4 7.4. ? Saturn Orbiter Performance 7-6 7.4. 3 Uranus Orbiter Performance 7-5 7.4.4 fflcts of Payload Mass Variation an. 7-8 Change in Launch Ve.hicl, Perfr:nancc 7. .. 5 P-erformnice I15.rfvenl(nt by C 3 7-10 Aug:.nntat ion Maneuver 7.4. 6 M!ission Ch;tracteristics Sum:narvy 7-13 7. 5 Comet Missiox: Performance 7-16 7.6 Auxiliary Propcllant Rcquirecrnts 7-18 7. 7 Prformanc, Noxzigrao}is 7-21 d. DEVELOPMENT.NT PLAN AND COST ASSESSMENT 8-I S. I Progranmaic Consideration:; 8-1 Vii CONTENTS (Continued) Page 8.2 Costing Guidelines 8-3 8.3 Cost Elements 8-4 8.4 Summary Development Schedule 8-4 8.4.1 N2 0 4 /MMMH Development Schedule 8-4 ' .8,4.2 Custom-De signed Propulsion Module 8-6 8.5 Development Cost Estimates 8-8 9. NEW TECHNOLOGY REQUIREMENTS AND 9-i COST EFFECTIVENESS 9. i Technology Advances Required for 9-I Multi-Mis sion Module 9. i. i Deployable Sun Shade 9-i 9. i. Z Engine Development 9-3 9.1.3 Long-Life Isolation Valve for -LF2 9-3 9. 1.4 LF Materials and Processes Technology 9-3 9. 1. 5 Development of Improved N.0 4 /MMH 9-4 Engine 9. 1.6 Development of Z lbf NZ0 4 /MMH ACS 9-4 Thrusters and N 2 0 4 j0-Year Life Capillary Acquisition Device 9. i. 7 Development of N 04/NZH4 Engines 9-4 9. Z Suggested Innovations 9-5 9. 2. 1 Concurrent Development of 200 and 9.5 800 lbf Engines 9.2.2 Concurrent Propulsion Module 9-5 Development 9. Z. 3 Conversion from N2 O4 /hIMH to 9-6 LF 2 IN2 4 9.3 Estimated New Technology Evolution, 9-6 Schedulks and Milestones 9.4 Cost Effectiveness Assessment 9-8 9.4. 1 Qualitative Assessment 9-8 9.4. Z Performance, Cost and Risk Consideration 9-13 9.4.3 Figure-of-Merit Analysis Examples 9-15 viii CONTENTS (Continued) Page 10.