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Design of a Green Monopropellant Propulsion System for the Lunar Flashlight Cubesat Mission

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Design of a Green Monopropellant Propulsion System for the Lunar Flashlight Cubesat Mission SSC20-IX-07 Design of a Green Monopropellant Propulsion System for the Lunar Flashlight CubeSat Mission Dawn Andrews Georgia Institute of Technology 305 Gull St, Manhattan Beach, CA 90266; (678) 634-9542 [email protected] Grayson Huggins Georgia Institute of Technology 1952 Cheyanne Dr SE, Smyrna, GA 30080; (404) 483-8519 [email protected] E. Glenn Lightsey, Nathan Cheek, Nathan Daniel Lee, Ali Talaksi, Sterling Peet, Lacey Littleton, Sahaj Patel, Logan Skidmore, Mackenzie Glaser Georgia Institute of Technology 620 Cherry St NW, Atlanta, GA 30332; (404) 385-4146 [email protected] Daniel Cavender, Hunter Williams, Don McQueen NASA Marshall Space Flight Center John Baker, Matt Kowalkowski NASA Jet Propulsion Laboratory ABSTRACT Lunar Flashlight is a 6U CubeSat mission from NASA's Jet Propulsion Laboratory that will search for water-ice deposits near the lunar south pole. Lunar Flashlight aims to add to the flight experience of deep-space CubeSats by demonstrating an orbit insertion using a green monopropellant propulsion system designed uniquely for this mission. Developed by NASA Marshall Spaceflight Center (MSFC) and Georgia Tech's Space Systems Design Laboratory (SSDL), the Lunar Flashlight Propulsion System (LFPS) delivers over 2500 N-s of total impulse for the orbit insertion and necessary attitude maneuvers. The custom propulsion system fits within a 2.5U volume and has a total wet mass of less than six kilograms. It will be fueled by AF-M315E, which is a green monopropellant developed by the Air Force Research Laboratory (AFRL) as a safer alternative to hydrazine. Additive manufacturing is utilized to fabricate several components of its primary structure. Upon completion, Lunar Flashlight may become the first CubeSat to achieve orbit around a celestial body besides Earth. The LFPS aims to be a pathfinder device for CubeSat missions by demonstrating how monopropellant systems, green monopropellant fuel, and additive manufacturing can be utilized to expand the reach of small satellite space exploration. INTRODUCTION responsibility for the design, manufacturing, test, and delivery of the Lunar Flashlight mission's propulsion The inclusion of propulsion systems on small satellites system. The Critical Design Review of the Lunar adds significant capability to their missions, allowing Flashlight Propulsion System (LFPS) was successfully them maneuverability, momentum control, and orbit completed in January of 2020, and the project has since adjustment. However, the design of small satellite proceeded into the manufacturing and integration phase. propulsion systems can be challenging due to their miniature size, custom architecture, and inclusion of Lunar Flashlight Mission cutting-edge technologies necessary for their success. The Lunar Flashlight mission is a 6U CubeSat that aims Under sponsorship by the NASA Marshall Space Flight to investigate the South pole of the Moon for volatiles including water ice.1 It will ride along with the Artemis- Center and the NASA Jet Propulsion Laboratory, the 1 mission on the Space Launch System (SLS) as part of Glenn Lightsey Research Group was awarded the United States' national effort to reestablish a human Andrews, et al. 1 34th Annual Small Satellite Conference presence on the moon. The Lunar Flashlight Propulsion LMP-103S and AF-M315E. Both of these are ‘green System accounts for approximately one half of the monopropellants,’ or hydroxylammonium nitrate-based spacecraft, filling about 2.5 of the total 6U. This alternatives whose most notable advantages include propulsion system will be responsible for momentum decreased toxicity and significantly safer storage and unloading as well as the insertion maneuver into the handling properties compared to Hydrazine.6 The LFPS science orbit. Upon the successful completion of this uses AF-M315E, which has also been designed to mission, Lunar Flashlight could become the first improve on the performance of hydrazine as shown in CubeSat to perform an orbit insertion and, subsequently, Table 1. the first CubeSat to explore the Moon. Table 1: Comparison of Hydrazine and AF- M315E Propellants Hydrazine AF-M315E Specific Gravity 1.015 1.467 Specific Impulse 190 seconds8 231 seconds9 Hazard Classification 85 1.4C7 The AF-M315E green monopropellant has flight heritage from one prior mission: the Green Propellant Infusion Mission (GPIM). GPIM was also managed by NASA MSFC, and it included engineering efforts by Figure 1: Concept Artwork of the Lunar Flashlight Aerojet Rocketdyne and Ball Aerospace. Its primary Mission2 objective was the technology demonstration of its AF- M315E propulsion system. It launched on June 25th, In addition to the main science objectives, the mission 2019 as part of the STP-2 mission on a Falcon Heavy will add to the flight heritage of green monopropellant rocket in a Ball Aerospace SmallSat platform.10 A week propulsion and be a technology demonstration for later, it reported successful firing of all five of its several of its supporting components. The microvalves, thrusters as part of system checkouts and an orbit micropump, and 100 mN thrusters will experience their lowering maneuver.11 first spaceflight, increasing their Technology Readiness Level (TRL) to 7. The inclusion of additive manufacturing in the flight hardware's fluid manifold structure and Propellant Management Device will both contribute to the growing number of use cases of additively manufactured materials in space. Finally, this system will be the first implementation of green monopropellant propulsion on a CubeSat platform, demonstrating this technology’s significant potential to expand the scope of exploration that is accessible to small satellite platforms. Green Monopropellant Propulsion Monopropellant propulsion is a decomposition-based form of chemical propulsion. The stored propellant is heated and flowed over a catalyst bed that triggers an exothermic reaction. This results in a high-temperature Figure 2: Test Fire of the GPIM Mission gaseous medium that may be accelerated out of a nozzle Thrusters12 to produce thrust. SYSTEM REQUIREMENTS Hydrazine has been in use for a very long time as a monopropellant, dating back to use as a rocket propellant The Lunar Flashlight Propulsion System was allocated in the 1930's.4 However, it is also notorious for being approximately 2 x 1 x 1.5 U volume within Lunar extremely toxic, carcinogenic, corrosive, flammable, and Flashlight's total 6U (where 1U is equivalent to 10cm or explosive.5 In NASA's 2020 Technology Taxonomy, 1000ccm) and was required to follow strict hydrazine alternatives were identified as a key specifications on its mechanical and electrical technology, specifically mentioning candidates such as interfacing to the rest of the spacecraft. The three major Andrews, et al. 2 34th Annual Small Satellite Conference requirements for the LFPS are shown in Table 2. thruster interface at the much higher required inlet Additional requirements included expected pressures. This allows the entire system to be low environmental loads, pre-determined interfaces, quality pressure (<100psi) when fully fueled, which simplifies standards, and more. and reduces risk for all ground handling and launch events. Table 2: Main Design Requirements Requirement Value Tank Design Wet Mass 5.5 kg The primary responsibility of the LFPS tank is to store Propellant Volume 1500 cc the propellant through launch and during operation of the Total Impulse 3000 N-s spacecraft. It contains the AF-M315E propellant and a Nitrogen ullage, as well as all components related to The design solution, which is shown in Figure 3, propellant filling, monitoring, and control in zero- includes a titanium structure that is split between a tank gravity. Its design was largely driven by strength and subassembly and a manifold subassembly. The manifold deformation requirements under static pressure loading. structure leverages the use of Laser Powder Bed Fusion The flight design is a Titanium 6Al-4V (Grade 5) (L-PBF) additive manufacturing. machined piece, joined by an EB weld seam through the center of the part. Within it is the full required internal propellant and ullage volume, as well as a Propellant Management Device (PMD) for on-orbit fluid management. On its exterior are mounting locations for the joint between spacecraft and propulsion system, between the tank and manifold, various sensors and the fill/drain port. Manifold Design In addition to the tank, the LFPS includes a manifold structure that houses all of the valves and fluid passages that are typical of many propulsion systems. The manifold is responsible for all fluid handling Figure 3: External Structure, As Presented at the downstream of the tank and its isolation valve. It LFPS Critical Design Review. structurally connects the tank, all four thrusters, the four thruster valves, and the pump and recirculation lines. Figure 4 shows the functional elements of the LFPS Internally, it contains all of the fluid passages that route shown in the style of a Piping and Instrumentation between those components. Diagram (P&ID). Notable elements include the pump and recirculation circuit, all sensor locations, and valve A functionally equivalent system made from traditional responsibilities for 1) bulk propellant isolation within the machining methods would require special equipment for tank and 2) controlled propellant feed to the thrusters. the miniscule flow passages, and several critical welds would be required. To make a similar design out of tubing and connectors,
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