Advanced Compatibility Characterization of AF-M315E with Spacecraft Propulsion System Materials Project

All spacecraft require propulsion systems for thrust and maneuvering. Propulsion systems can be chemical, nuclear, electrical, cold gas or combinations thereof. Chemical propulsion has proven to be the most reliable technology since the deployment of launch vehicles. Performance, storability, and handling are three important aspects of liquid chemical propulsion. Bipropellant systems require a fuel and an oxidizer for propulsion, but monopropellants only require a fuel and a catalyst for propulsion and are therefore simpler and lighter. Hydrazine is the state of the art propellant for monopropellant systems, but has drawbacks because it is highly hazardous to human health, which requires extensive care in handling, complex ground ops due to safety and environmental considerations, and lengthy turnaround times for reusable spacecraft. All users of hydrazine monopropellant must contend with these issues and their associated costs. The development of a new monopropellant, intended to replace hydrazine, has been in progress for years. This project will apply advanced techniques to characterize the engineering properties of materials used in AF-M315E propulsion systems after propellant exposure. AF-M315E monopropellant has been selected HQ's Green Propellant Infusion Mission (GPIM) to replace toxic hydrazine for improved performance and reduce safety and health issues that will shorten reusable spacecraft turn-around time. In addition, this project will fundamentally strengthen JSC's core competency to evaluate, use and infuse liquid propellant systems. This project will apply advanced techniques to characterize the engineering properties of materials used in AF-M315E propulsion systems after propellant exposure. AF-M315E monopropellant has been selected by NASA HQ's Green Propellant Infusion Mission (GPIM) to replace toxic hydrazine for improved performance and reduce safety and health issues that will shorten reusable spacecraft turn-around time. The compatibility of propulsion system materials with AF-M315E is not well characterized and a specification for the propellant has not been finalized. The corrosion and degradation properties of materials available to design engineers will be examined and corrosion/degradation will be reduced by surface modification. This work will provide data for the selection and improvement of candidate materials used in AF-M315E spacecraft propulsion systems with potential applications to ground support equipment and an improved propellant specification. WSTF has developed and used in previous work the infrastructure and experience to perform the tests which AF-M315E's classification as an explosive requires. The goal of this project is to provide enhanced material and fluid compatibility data for designers to build spacecraft and GSE with a higher degree of confidence. In addition, a specification suitable for characterizing the fluid will be provided. The compatibility of propulsion system materials with AF-M315E is not well characterized, there is little information in the literature, and few entities have performed material and fluid compatibility testing. In addition, this project will fundamentally strengthen JSC's core competency to evaluate, use and infuse liquid propellant systems.

White Sands Test Facility (WSTF) has been engaged in compatibility testing and has taken the lead in laboratory testing for all of NASA. This project will extend and apply advanced techniques to characterize the engineering properties of materials used in AF-M315E propulsion systems after propellant exposure and to characterize the propellant during and after exposure. Materials including metals, non-metals, composites and advanced materials will be exposed to AF-M315E under various conditions including accelerated aging conditions and post-immersion materials and fluid properties will be examined. Advanced materials will be identified in collaboration with the user community. This work will provide data for the selection of candidate materials used in AF-M315E propulsion systems with potential applications to ground support equipment as well as to apply surface modification techniques to improve material compatibility. For example, the improvement of aluminum and titanium alloy compatibility with respect to corrosion will be addressed. In addition to the materials testing aspect of this project, the fluid characterization aspect of the project will be addressed. A draft military specification for AF-M315E will be evaluated and input provided to the preparing organization. Evaluation of the draft specification will include trial and examination of the proposed testing protocols and the resolution of inherent issues and issues that are found. The draft military specification will serve as an important part as a basis for evaluating posttest fluid characteristics. Evaluating and improving the draft specification is also part of this project because the analyses are numerous and complex and WSTF chemists experienced in propellant specification analysis will apply innovative techniques to improve and lower the cost of a specification analysis.#AF-M315E offers greatly reduced toxicity, safety, and environmental issues, as well as increased performance compared to hydrazine. AF-M315E monopropellant has been selected by NASA's Headquarters (HQ) Space Technology and Mission Directorate Green Propellant Infusion Mission (GPIM) as a candidate to replace monopropellant hydrazine. As a new propellant, many engineering issues require solutions. One of the most important of these is materials selection. The fluid must be compatible with the materials that are used to preserve the integrity of both the fluid and the propellant, and a specification is needed to define fluid quality. The goal of this project is to provide enhanced material and fluid compatibility data for designers to build spacecraft and GSE with a higher degree of confidence. In addition, a specification suitable for characterizing the fluid will be provided. The compatibility of propulsion system materials with AF-M315E is not well characterized, there is little information in the literature, and few entities have performed material and fluid compatibility testing.

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