Orbital transfer rocket engine technology: Advanced engine study

An advanced LOX/LH2 engine study for the use of NASA and vehicle prime contractors in developing concepts for manned missions to the Moon, Mars, and Phobos is documented. Parametric design data was obtained at five engine thrusts from 7.5K lbf to 50K lbf. Also, a separate task evaluated engine throttling over a 20:1 range and operation at a mixture ratio of 12 plus or minus 1 versus the 6 plus or minus 1 nominal. Cost data was also generated for DDT&E, first unit production, and factors in other life cycle costs. The major limitation of the study was lack of contact with vehicle prime contractors to resolve the issues in vehicle/engine interfaces. The baseline Aerojet dual propellant expander cycle was shown capable of meeting all performance requirements with an expected long operational life due to the high thermal margins. The basic engine design readily accommodated the 20:1 throttling requirement and operation up to a mixture ratio of 10 without change. By using platinum for baffled injector construction the increased thermal margin allowed operation up to mixture ratio 13. An initial engine modeling with an Aerojet transient simulation code (named MLETS) indicates stable engine operation with the baseline control system. A throttle ratio of 4 to 5 seconds from 10 percent to 100 percent thrust is also predicted. Performance predictions are 483.1 sec at 7.5K lbf, 487.3 sec at 20K lbf, and 485.2 sec at 50K lbf with a mixture ratio of 6 and an area ratio of 1200. Engine envelopes varied from 120 in. length/53 in. exit diameter at 7.5K lbf to 305 in. length/136 in. exit diameter at 50 K lbf. Packaging will be an important consideration. Continued work is recommended to include more vehicle prime contractor/engine contractor joint assessment of the interface issues.