Presentation from the International Space and Development Conference 2009 in Orlando, FL.

1. Liquid Bi-Propellant Rocket Development for Lunar Lander Presenters: Sarah Baber – Impulse Rocketry Technology, Project Manager 2008-2009 Johann Schrell – Team Cynthion, Project Manager & Performance Director 2007-2008 1

2. The Challenge Northrop Grumman Lunar Lander Challenge Tasked in 2007 with creating design for viable university entry Design the propulsion system for a separately designed lunar lander vehicle Must be capable of propelling vehicle: Minimum 50 meters vertical Minimum 100-120 meters translation Minimum 90 seconds hover Into a soft landing Propulsion was designed around these requirements and the requirements of the vehicle designers Team acted as subcontractor to vehicle designers 2

3. The Teams Two years, two teams Team Cynthion 2007-2008 Worked from requirements set forth by vehicle designers and competition Developed detailed designs and analysis Completed manufacture of parts Impulse Rocketry Technology 2008-2009 Worked from requirements set forth by competition Developed detailed designs and analysis Completed manufacture and assembly of all engine components Completed detailed design and assembly of test equipment and feed system Teams consisted of undergraduate aerospace engineering seniors 3

4. Learning Experience Real-world engineering environment Design process Team interaction Customer interaction Outsourcing Communicating with Machinists Research Skills Engineering Software MatLab Catia CAD NEiNastran FEA STAR CCM+ with CFD NASA CEA Thermochemical analysis LabView 4

5. Economics Common materials No exotic materials means a cheaper solution Simple machining Components designed for ease of manufacture to cut machining costs Non-aerospace grade parts Components purchased from suppliers such as McMaster Components purchased rated high for large operating safety margins Money saved and reliability maintained Common propellants High performance achieved without exotic costly propellants and storage equipment 5

6. Propellants Propane Pros: Readily available, stable, must be pressurized to ignite without open flame or spark, inexpensive Cons: Difficult to arrange for a high pressure certified tank to be filled, flammable when in unconfined space as a gas, little rocketry data available Methanol Pros: Readily available in jugs, easy to fill a high pressure tank, stays liquid at standard atmosphere Cons: Flame spreads on ground if leaked, volatile if ingested or inhaled, little rocketry data available Nitrous Oxide Pros: Readily available from race shops, self pressurizes, lots of data available, stable, non-toxic, non-cryogenic Cons: Difficult to purchase pure N2O (most has SO2 additive), not as capable as LOX or peroxide 6

7. Team Cynthion The Engine Approx 1000 lbf max thrust Fuel: Liquid Propane (C3H8) Oxidizer: Nitrous Oxide (N2O) Common grade materials Designed for restart and throttle capability Full regenerative cooling system for thermal protection 7

8. Team Cynthion Performance 8

9. Team Cynthion Analysis Highest stresses in cooling jacket CFD confirms flow velocity 9

10. Team Cynthion Components and Materials Chamber Copper Nozzle Copper Cooling Sleeve Low Carbon Steel Injector Plate and Oxidizer Dome Stainless Steel Connector Plates Low Carbon Steel and Copper Fuel Intake Manifold Brass 10

11. Team Cynthion Unique Design Aspects Cooling Jacket Single Channel Full Jacket Less Time and Money for Manufacturing Fewer Welding/Braising Points Allows Side Injection Low Voltage Glow Plug Ignition Weight savings on power systems Safer operation 11

12. Impulse Rocketry Technology The Engine Approx 850 lbf max thrust as designed Approx 250 lbf max thrust as built for subscale testing Fuel: Methanol (CH3OH) Oxidizer: Nitrous Oxide (N2O) Common grade materials Designed for restart and throttle capability Ablative and regenerative cooling system for thermal protection $3500 manufacturing and testing budget 12

13. Impulse Rocketry Technology Performance 13

14. Impulse Rocketry Technology Components and Materials Chamber Low Carbon Steel Nozzle Graphite Nozzle Holder Low Carbon Steel Injector Plate Low Carbon Steel Connector Plate Low Carbon Steel Gasket Rings Copper Ablative ITC Ceramic Coatings 14

15. Impulse Rocketry Technology Stress Analysis 15

16. Impulse Rocketry Technology Unique Design Aspects Chamber Cooling Jacket (Similar to Cynthion) Graphite Converging Diverging Nozzle Using off the shelf products wherever possible ITC Paint Nuts, Bolts, and Washers Spark Plug Feed System Plumbing Impinging Oxidizer Injectors Modular parts for easy alteration 16

17. Application of Work Implications outside the student project environment. Affordable small propulsion systems for soft landers Space privatization X-prize Low complexity systems Easy troubleshooting Quick installation Less training required for technicians Low toxicity household name chemicals as propellants Safe handling Environmentally friendly combustion relative to solids, hypergolics, and Kerosene based fuels 17

18. Praise and Questions Thanks to all that have made this project possible Dr. Eric Perrell, ERAU Dr. Geoffrey Kain Dr. Frank Radosta, ERAU Bill Russo, ERAU Rich Hedge, ERAU Michael Potash, ERAU Mohammad Naraghi, ERAU Advanced Machining, New Smyrna, FL Questions and discussion 18