Part III Chapter 1
And we're back!
Part III Chapter 1:
“The ultimate in hydrogen motors is the nuclear rocket. As we have seen, the way to get a really high performance is to heat hydrogen to 2000 K or so, and then expand it through a nozzle. A graphite-moderated enriched uranium reactor is the energy source, and the hydrogen is the working fluid.”
-Ignition! An Informal History of Liquid Rocket Propellants John D. Clark, 1972
One of the most important enabling technologies for the Ares program was Nuclear Thermal Propulsion. This new type of rocket would use a nuclear core to heat up liquid hydrogen, which would be used to generate thrust. Doing so would nearly the double the efficiency compared to hydrogen/oxygen engines. This increase in efficiency would cut down the mass in orbit needed for each Ares mission by nearly a factor of two. Still, despite these savings, out of the four launches required for each flight to Mars, three would carry Planetary Propulsion Modules. Like every other major component of the mission, the PPM was more complicated than and would need to be more reliable than, any previous piece of hardware launched into space. Each PPM would carry 170 tons of hydrogen propellant and would mass 75 tons dry. It would be powered by 2 NR-1 Nuclear Thermal Rocket engines, each having a specific impulse of 850 seconds. The PPM would have to be able to prevent the hydrogen from boiling off for almost two years, and would accomplish this using a complicated system involving heat radiator panels, refrigeration and reliquification systems, and thick layers of insulation.
These critical technologies would be tested in October of 1973 by the Technology Demonstration Flight 1. TDF-1 would be launched on the final flight of the Saturn 1B. The TDF-1 payload was just a small prototype of the cryogenic storage equipment, and some solar panels to power it. TDF-1 lifted off on the 11th, and reached orbit with plenty of propellant left in the S-IVB. Using the new equipment, and extra insulation installed on the S-IVB, ground control monitored how much hydrogen boiled off over the next few weeks on orbit. The results were disappointing. Although the modifications limited boil off to just 0.5% per week, that would still equate to 46% losses over the 92 week flight to Mars. Further improvements would be needed.
On March 15, 1975, a Saturn V lifted off from Florida, carrying a very special payload. This flight, labeled as simply TDF-2, would be the first in flight test of the NR-2 NTR engine. Like on TDF-1, the payload on this flight was a modified S-IVB. This time however, the oxygen tank on the S-IVB had been removed, and the hydrogen tank extended. The lower density of hydrogen meant that only around 22 tons of propellant were carried. In fact, due to the added mass of insulation, cryogenic storage equipment, shielding, and the NR-2 itself, the dry mass of the S-IVN upper stage was greater than the propellant carried, at over 24 tons. This payload was far less than the capacity of the Saturn V, so the extra performance was used to lift the S-IVN into a higher orbit, to prevent it from impacting Earth if it failed. The presence of a nuclear reactor aboard TDF-2 led a few environmental activists to protest the launch, but the general public response was curiosity. It had to be explained to many that this rocket stage was not powered by nuclear bombs, but more mundane hydrogen.
Despite the low mass fraction, the S-IVN had over 5 kilometers per second of Delta V. This capacity would not be used in full however, as the second goal of the TDF-2 mission was to demonstrate more advanced long term cryogenic storage techniques. After a few test fires of the NR-2, the stage was essentially just left on orbit for a few weeks to test the technology. This time, results were more promising, with boil off reduced to just 0.07% per month. Improvements would be needed, but the test was declared successful. After the cryo tests, the NR-2 was reignited, and sent into orbit around the sun, onto a trajectory that would not have a chance to impact Earth for over a million years. Ares mission planners had reached out to the unmanned exploration division, and asked if any one wanted to fly their probe on TDF-2. The requirements were that it mass under 200kg, not require any specific launch window, and, obviously, be ok with flying on a test flight of a nuclear rocket. Taken aback, several different teams quickly worked to develop a design. In the end, the Solar Environment Explorer was chosen. SEE was based on the same design as the cancelled Mercury Mariner spacecraft, and would study solar winds and the makeup of the sun. The S-IVN placed it onto an inclined orbit that almost reached Mercury's orbit, and the spacecraft separated and began its mission on May 9.
Originally, NASA had decided to use all five of the Saturn Vs left over from Apollo for test flights. Two were intended to launch the Skylab and Starlab space stations, one would be used for the nuclear test, and two would be used for testing the MEM. However, the Saturn VB would be flying by 1977, and the new rocket was different enough from the Saturn V that substantial modifications would need to be made to the pad. So it was decided that no Saturn Vs would fly after 1975. The MEM tests would instead fly on the Saturn VA (a variant of the VB without boosters) starting in 1978. This would leave two Saturn Vs unused. It was decided to fly a repeat of the TDF-2 mission using one of them, and so, after the launch of Starlab in July of 1975, TDF-3 lifted off in November. The flight path was almost identical, with the cryogenic storage tests going a little better. A critical test performed by the TDF-3 flight was multiple restarts of the NR-2 engine. For a mission to Mars, each engine would have to restart three times, and so this capability was critical. The S-IVN would raise and lower its orbit over several months. Finally, the stage was fired a final time to launch it into a heliocentric orbit. This time however, the disposal orbit was launched outwards, past the orbit of Mars. Like with TDF-2, a “hitchhiker payload” flew along, however, this time it was an engineering payload. The “Deep Space Radiation Experiment” separated from the stage, and once it was sufficiently clear from any interference from the engine, began examining the levels of radiation a spacecraft would experience traveling to Mars. This was a relatively new concern that scientists had for a Mars mission. Throughout late 1972 and early 1973, solar activity rose to an all time high. Massive solar flares spat out radiation into space. The crew of Skylab were protected by the natural magnetic field of Earth, but had any astronauts been traveling to the Moon or Mars at that point, they might have received a potentially fatal dose of solar radiation. The designers studying how to build a habitat to sustain crews on the way to Mars began including additional radiation shielding into their designs. In the center of the habitat would also be a “Storm Shelter”, to protect the crew. The spacecraft would also be oriented so that the propulsion a structural elements of the ship would be positioned between the crew and the sun, to further shield them. DSRE measured the radiation levels, and also tested out shielding technologies.
After this flight, the last unused Saturn V, SA-514, would join the ground test vehicles as a museum piece, and would be put on display at the Johnson Space Center in Houston. It remained the last of the original production run Saturn Vs.
Part III Chapter 1:
“The ultimate in hydrogen motors is the nuclear rocket. As we have seen, the way to get a really high performance is to heat hydrogen to 2000 K or so, and then expand it through a nozzle. A graphite-moderated enriched uranium reactor is the energy source, and the hydrogen is the working fluid.”
-Ignition! An Informal History of Liquid Rocket Propellants John D. Clark, 1972
One of the most important enabling technologies for the Ares program was Nuclear Thermal Propulsion. This new type of rocket would use a nuclear core to heat up liquid hydrogen, which would be used to generate thrust. Doing so would nearly the double the efficiency compared to hydrogen/oxygen engines. This increase in efficiency would cut down the mass in orbit needed for each Ares mission by nearly a factor of two. Still, despite these savings, out of the four launches required for each flight to Mars, three would carry Planetary Propulsion Modules. Like every other major component of the mission, the PPM was more complicated than and would need to be more reliable than, any previous piece of hardware launched into space. Each PPM would carry 170 tons of hydrogen propellant and would mass 75 tons dry. It would be powered by 2 NR-1 Nuclear Thermal Rocket engines, each having a specific impulse of 850 seconds. The PPM would have to be able to prevent the hydrogen from boiling off for almost two years, and would accomplish this using a complicated system involving heat radiator panels, refrigeration and reliquification systems, and thick layers of insulation.
These critical technologies would be tested in October of 1973 by the Technology Demonstration Flight 1. TDF-1 would be launched on the final flight of the Saturn 1B. The TDF-1 payload was just a small prototype of the cryogenic storage equipment, and some solar panels to power it. TDF-1 lifted off on the 11th, and reached orbit with plenty of propellant left in the S-IVB. Using the new equipment, and extra insulation installed on the S-IVB, ground control monitored how much hydrogen boiled off over the next few weeks on orbit. The results were disappointing. Although the modifications limited boil off to just 0.5% per week, that would still equate to 46% losses over the 92 week flight to Mars. Further improvements would be needed.
On March 15, 1975, a Saturn V lifted off from Florida, carrying a very special payload. This flight, labeled as simply TDF-2, would be the first in flight test of the NR-2 NTR engine. Like on TDF-1, the payload on this flight was a modified S-IVB. This time however, the oxygen tank on the S-IVB had been removed, and the hydrogen tank extended. The lower density of hydrogen meant that only around 22 tons of propellant were carried. In fact, due to the added mass of insulation, cryogenic storage equipment, shielding, and the NR-2 itself, the dry mass of the S-IVN upper stage was greater than the propellant carried, at over 24 tons. This payload was far less than the capacity of the Saturn V, so the extra performance was used to lift the S-IVN into a higher orbit, to prevent it from impacting Earth if it failed. The presence of a nuclear reactor aboard TDF-2 led a few environmental activists to protest the launch, but the general public response was curiosity. It had to be explained to many that this rocket stage was not powered by nuclear bombs, but more mundane hydrogen.
Despite the low mass fraction, the S-IVN had over 5 kilometers per second of Delta V. This capacity would not be used in full however, as the second goal of the TDF-2 mission was to demonstrate more advanced long term cryogenic storage techniques. After a few test fires of the NR-2, the stage was essentially just left on orbit for a few weeks to test the technology. This time, results were more promising, with boil off reduced to just 0.07% per month. Improvements would be needed, but the test was declared successful. After the cryo tests, the NR-2 was reignited, and sent into orbit around the sun, onto a trajectory that would not have a chance to impact Earth for over a million years. Ares mission planners had reached out to the unmanned exploration division, and asked if any one wanted to fly their probe on TDF-2. The requirements were that it mass under 200kg, not require any specific launch window, and, obviously, be ok with flying on a test flight of a nuclear rocket. Taken aback, several different teams quickly worked to develop a design. In the end, the Solar Environment Explorer was chosen. SEE was based on the same design as the cancelled Mercury Mariner spacecraft, and would study solar winds and the makeup of the sun. The S-IVN placed it onto an inclined orbit that almost reached Mercury's orbit, and the spacecraft separated and began its mission on May 9.
Originally, NASA had decided to use all five of the Saturn Vs left over from Apollo for test flights. Two were intended to launch the Skylab and Starlab space stations, one would be used for the nuclear test, and two would be used for testing the MEM. However, the Saturn VB would be flying by 1977, and the new rocket was different enough from the Saturn V that substantial modifications would need to be made to the pad. So it was decided that no Saturn Vs would fly after 1975. The MEM tests would instead fly on the Saturn VA (a variant of the VB without boosters) starting in 1978. This would leave two Saturn Vs unused. It was decided to fly a repeat of the TDF-2 mission using one of them, and so, after the launch of Starlab in July of 1975, TDF-3 lifted off in November. The flight path was almost identical, with the cryogenic storage tests going a little better. A critical test performed by the TDF-3 flight was multiple restarts of the NR-2 engine. For a mission to Mars, each engine would have to restart three times, and so this capability was critical. The S-IVN would raise and lower its orbit over several months. Finally, the stage was fired a final time to launch it into a heliocentric orbit. This time however, the disposal orbit was launched outwards, past the orbit of Mars. Like with TDF-2, a “hitchhiker payload” flew along, however, this time it was an engineering payload. The “Deep Space Radiation Experiment” separated from the stage, and once it was sufficiently clear from any interference from the engine, began examining the levels of radiation a spacecraft would experience traveling to Mars. This was a relatively new concern that scientists had for a Mars mission. Throughout late 1972 and early 1973, solar activity rose to an all time high. Massive solar flares spat out radiation into space. The crew of Skylab were protected by the natural magnetic field of Earth, but had any astronauts been traveling to the Moon or Mars at that point, they might have received a potentially fatal dose of solar radiation. The designers studying how to build a habitat to sustain crews on the way to Mars began including additional radiation shielding into their designs. In the center of the habitat would also be a “Storm Shelter”, to protect the crew. The spacecraft would also be oriented so that the propulsion a structural elements of the ship would be positioned between the crew and the sun, to further shield them. DSRE measured the radiation levels, and also tested out shielding technologies.
After this flight, the last unused Saturn V, SA-514, would join the ground test vehicles as a museum piece, and would be put on display at the Johnson Space Center in Houston. It remained the last of the original production run Saturn Vs.
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