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NASA Marshall Engineers Unveil Versatile, Low-cost Hybrid Engine Testbed


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Preparations for Next Moonwalk Simulations Underway (and Underwater)

A pair of NASA engineers conduct checkout testing of a new hybrid rocket engine testbed, a long, blue, cylindrical facility for testing new government and industry rocket motor hardware, materials, and propellants at NASA’s Marshall Space Flight Center.
Paul Dumbacher, right, lead test engineer for the Propulsion Test Branch at NASA’s Marshall Space Flight Center in Huntsville, Alabama, confers with Meredith Patterson, solid propulsion systems engineer, as they install the 11-inch hybrid rocket motor testbed into its cradle in Marshall’s East Test Stand. The new testbed, offering versatile, low-cost test opportunities to NASA propulsion engineers and their government, academic, and industry partners, reflects the collaboration of dozens of team members across multiple departments at Marshall.
NASA/Charles Beason

In June, engineers at NASA’s Marshall Space Flight Center in Huntsville, Alabama, unveiled an innovative, 11-inch hybrid rocket motor testbed.

The new hybrid testbed, which features variable flow capability and a 20-second continuous burn duration, is designed to provide a low-cost, quick-turnaround solution for conducting hot-fire tests of advanced nozzles and other rocket engine hardware, composite materials, and propellants.

Solid rocket propulsion remains a competitive, reliable technology for various compact and heavy-lift rockets as well as in-space missions, offering low propulsion element mass, high energy density, resilience in extreme environments, and reliable performance.

“It’s time consuming and costly to put a new solid rocket motor through its paces – identifying how materials perform in extreme temperatures and under severe structural and dynamic loads,” said Benjamin Davis, branch chief of the Solid Propulsion and Pyrotechnic Devices Branch of Marshall’s Engineering Directorate. “In today’s fast-paced, competitive environment, we wanted to find a way to condense that schedule. The hybrid testbed offers an exciting, low-cost solution.”

Initiated in 2020, the project stemmed from NASA’s work to develop new composite materials, additively manufactured – or 3D-printed – nozzles, and other components with proven benefits across the spacefaring spectrum, from rockets to planetary landers.

After analyzing future industry requirements, and with feedback from NASA’s aerospace partners, the Marshall team recognized that their existing 24-inch rocket motor testbed – a subscale version of the Space Launch System booster – could prove too costly for small startups. Additionally, conventional, six-inch test motors limited flexible configuration and required multiple tests to achieve all customer goals. The team realized what industry needed most was an efficient, versatile third option.

“The 11-inch hybrid motor testbed offers the instrumentation, configurability, and cost-efficiency our government, industry, and academic partners need,” said Chloe Bower, subscale solid rocket motor manufacturing lead at Marshall. “It can accomplish multiple test objectives simultaneously – including different nozzle configurations, new instrumentation or internal insulation, and various propellants or flight environments.”

“That quicker pace can reduce test time from months to weeks or days,” said Precious Mitchell, solid propulsion design lead for the project.

Three female NASA engineers conduct post-test analysis of disassembled, cylindrical components of a new, hybrid rocket motor testbed at NASA’s Marshall Space Flight Center.
Engineers at NASA’s Marshall Space Flight Center in Huntsville, Alabama, assess components of the 11-inch hybrid rocket motor testbed in the wake of successful testing in June. Among Marshall personnel leading in-house development of the new testbed are, from left, Chloe Bower, subscale solid rocket motor manufacturing lead; Jacobs manufacturing engineer Shelby Westrich; and Precious Mitchell, solid propulsion design lead.
NASA/Benjamin Davis

Another feature of great interest is the on/off switch. “That’s one of the big advantages to a hybrid testbed,” Mitchell continued. “With a solid propulsion system, once it’s ignited, it will burn until the fuel is spent. But because there’s no oxidizer in hybrid fuel, we can simply turn it off at any point if we see anomalies or need to fine-tune a test element, yielding more accurate test results that precisely meet customer needs.”

The team expects to deliver to NASA leadership final test data later this summer. For now, Davis congratulates the Marshall propulsion designers, analysts, chemists, materials engineers, safety personnel, and test engineers who collaborated on the new testbed.

“We’re not just supporting the aerospace industry in broad terms,” he said. “We’re also giving young NASA engineers a chance to get their hands dirty in a practical test environment solving problems. This work helps educate new generations who will carry on NASA’s mission in the decades to come.”

For nearly 65 years, Marshall teams have led development of the U.S. space program’s most powerful rocket engines and spacecraft, from the Apollo-era Saturn V rocket and the space shuttle to today’s cutting-edge propulsion systems, including NASA’s newest rocket, the Space Launch System. NASA technology testbeds designed and built by Marshall engineers and their partners have shaped the reliable technologies of spaceflight and continue to enable discovery, testing, and certification of advanced rocket engine materials and manufacturing techniques. 

Learn more about NASA Marshall capabilities at:

https://www.nasa.gov/marshall-space-flight-center-capabilities

Ramon J. Osorio
Marshall Space Flight Center, Huntsville, Alabama
256-544-0034
ramon.j.osorio@nasa.gov

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Last Updated
Jul 12, 2024
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Beth Ridgeway

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      NASA astronaut Nick Hague suits up for spacewalk training in the Neutral Buoyancy Laboratory. NASA/James Blair Hague has made many memories at Johnson, but one that stands out is his experience working onsite amid the 2013 government shutdown. “I’m active-duty military so I still came to work,” he explained. “I remember being onsite and the center being completely empty. Being able to ride around an empty campus on the free-range bikes – it was peaceful and surreal.” It was also a preview of what many Johnson employees experienced during the pandemic and how NASA maintains round-the-clock support for spaceflight operations regardless of extenuating circumstances.

      Hague now looks ahead to another journey to low Earth orbit. NASA and SpaceX officials currently plan to launch the Crew-9 mission no earlier than Wednesday, Sept. 25. The crew will lift off from Launch Complex 40 from the Cape Canaveral Space Force Station in Florida aboard a SpaceX Falcon 9 rocket and Dragon spacecraft.

      Roscosmos cosmonaut Aleksandr Gorbunov (left) and NASA astronaut Nick Hague during a visit to Kennedy Space Center for training. SpaceX Hague and Gorbonov will become members of the Expedition 72 crew aboard the station. They will join NASA astronauts Butch Wilmore, Suni Williams, and Don Pettit, and Roscosmos cosmonauts Alexey Ovchinin and Ivan Vagner, and will spend about six months conducting scientific research in microgravity and completing a range of operational activities before returning home.

      More details about the mission and crew can be found by following the Crew-9 blog, @commercial_crew on X, or commercial crew on Facebook. You can also follow @astrohague on X and Instagram.
      View the full article
    • By NASA
      Students are recognized for their hard work in STEM-related extended-day programs at their school through a partnership with NASA’s Langley Research Center in Hampton, Virginia.Credit: NASA Media are invited to the kickoff event of a collaboration between NASA and the U.S. Department of Education at 4 p.m. EDT Monday, Sept. 23, at the Wheatley Education Campus in Washington. The interagency project, 21st Century Community Learning Centers, aims to engage students in science, technology, engineering, and math (STEM) education during after-school hours.
      During the event, media will have the opportunity to learn about the STEM collaboration, hear remarks from leadership, and have one-on-one interviews with NASA and Education Department officials upon request. Additionally, students will have the opportunity to engage in educational activities, as well as participate in an engineering design challenge.
      Officials providing remarks at the event include:
      Kris Brown, deputy associate administrator, NASA’s Office of STEM Engagement, Headquarters in Washington Cindy Marten, deputy secretary, U.S. Department of Education Media interested in covering the event must RSVP no later than Friday, Sept. 20, to Abbey Donaldson: abbey.a.donaldson@nasa.gov.
      Through the project, NASA’s Glenn Research Center in Cleveland and the Education Department will align resources to provide STEM activities, professional development, and funding for after-school programs nationwide. NASA will offer staff training, continuous program support, and opportunities for students to engage with NASA scientists and engineers. The initiative also will include student activities that demonstrate practical applications of STEM concepts.
      In May 2023, NASA and the Education Department signed a Memorandum of Understanding, strengthening the collaboration between the two agencies, and expanding efforts to increase access to high-quality STEM and space education to students and schools across the nation. NASA Glenn signed a follow-on Space Act Agreement in 2024 to support the 21st Century Community Learning Centers.
      Learn more about how NASA’s Office of STEM Engagement is inspiring the next generation of explorers at:
      https://www.nasa.gov/stem
      -end-
      Abbey Donaldson
      Headquarters, Washington
      202-269-1600
      abbey.a.donaldson@nasa.gov
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      Last Updated Sep 18, 2024 EditorJessica TaveauLocationNASA Headquarters Related Terms
      STEM Engagement at NASA Learning Resources Opportunities For Students to Get Involved Partner with NASA STEM View the full article
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