Compact Microtube Igniter for Methane Rockets

This project seeks to facilitate the Evolvable Mars Campaign (EMC) LOX/Methane Propulsion Architecture by developing a reliable, compact, low power methane igniter. One of the key technical challenges to the use of oxygen-methane is the demonstration of reliable ignition over the potential operating envelope of Reaction Control system (RCS) thrusters. These thrusters have a minimum impulse bit and widely varying duty cycles. Reliable and repeatable demonstrations of cold start and restart with heat soak-back are required to mitigate the risk. Recent tests with the Integrated Cryogenic Propulsion Test Article (ICPTA) at Plumb Brook Station reveal that it is difficult to light the LOX/Methane reaction control engines after cold soak with the spark torch. Multiple attempts were made, but in all but one case the result was a cold flow test with no ignition. Alternative and redundant catalytic ignition systems will have alternative failure modes, draw less power, negate the high voltage discharge and sizable exciter hardware that spark systems require and can eliminate common cause failure modes to provide an additional layer of safety to the manned missions. The goal is to provide critical ignition technology for oxygen-methane propulsion for reliable spacecraft propulsion.

State-of-the-art Reaction Control Engine (RCE) technology is based on the use of toxic hypergolic propellants and has not been updated since the 1960s. Their use results in high operating costs and Extra Vehicular Activity (EVA) hazards for manned vehicles. Plans are underway to mitigate the safety concerns and operating costs that burden these propellants by using nontoxic cryogenic propellants. In-situ resource utilization on a future trip to Mars also creates a driver for the use of oxygen-methane, which has the potential for improved performance and reduced cost over the hypergolic propellants in the RCS. Reliable ignition is an enabling technology for the acceptance and use of methane as a rocket propellant. Producing propellant via In-Situ Resource Utilization (ISRU) will enable missions with chemical propulsion by the "refueling" of return-trip propellant. It will reduce vehicle propellant mass carrying requirement by over 50%.

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