Confidence Testing of Shell 405 and S-405 Catalysts in a Monopropellant Hydrazine Thruster

As part of the transfer of catalyst manufacturing technology from Shell Chemical Company (Shell 405 catalyst manufactured in Houston, Texas) to Aerojet (S-405 manufactured in Redmond, Washington), Aerojet demonstrated the equivalence of S-405 and Shell 405 at beginning of life. Some US aerospace users expressed a desire to conduct a preliminary confidence test to assess end-of-life characteristics for S-405. NASA Marshall Space Flight Center (MSFC) and Aerojet entered a contractual agreement in 2004 to conduct a confidence test using a pair of 0.2-lbf MR-103G monopropellant hydrazine thrusters, comparing S-405 and Shell 405 side by side. This paper summarizes the formulation of this test program, explains the test matrix, describes the progress of the test, and analyzes the test results. This paper also includes a discussion of the limitations of this test and the ramifications of the test results for assessing the need for future qualification testing in particular hydrazine thruster applications.