SBIR-STTR Award

Orion Propulsion, Inc. proposes to develop an Oxygen and Methane RCS Thruster to advance the technology of alternate fuels. A successful Oxygen/CH4 RCS Thruster will also be new reaction control engine that integrates readily with integrates readily with primary propulsion by using the same propellants. Orion has a developed a preliminary design of an Oxygen / Methane (O/M) RCS Thruster, and our purpose is to contribute to NASA Space Exploration goals by increasing the technology readiness of oxygen/methane rocket systems. Orion has demonstrated the current development status of our thruster with some 40 firings at sea level. The objective of the Phase 1 R&D would be to improve credibility of its design by testing another prototype test article, which is equipped with a flight type nozzle and propellant valves. These tests would be performed in a environmental chamber at reduced pressure to simulate space vacuum conditions. Although, the O/M Thruster test article would be constructed of stainless steel, its interior would be coated with a refractory metal alloy. This treatment enables the test article to sustain higher temperatures and enables longer tests. The expected result of a Phase 2 effort would be a flight-ready prototype thruster for delivery to NASA.

Two main innovations will be developed in the Phase II effort that are fundamentally associated with our gaseous oxygen/gaseous methane RCS thruster. The first innovation is that of an integrated torch igniter/injector which, provides simple and reliable ignition for the thruster. The second innovation is the thruster's capability to operate with both gaseous and liquid propellants. This innovation enables greater system flexibility that is inherent in the capacity to function over a much wider range of operating conditions. Orion has been approached by several prospective customers concerning affordable, reusable thrusters. In the current commercial market, this does not exist and the commercial sector cannot afford traditional propulsion solutions. For this reason, Orion started developing a thruster that offers the following features: * Provides an affordable solution as compared to what is currently available * Uses a different manned approach since it is reusable * Uses a modular design, which allows for the robust inspection and replacement of parts * Uses green propellants and capitalizes on in situ propellant production * Provides greater system flexibility since it operates with both liquid and gaseous propellants Not only does the gas/gas operation of the thruster attract companies such as t/Space and Bigleow Aerospace, but its liquid/liquid operation broadens this customer base and makes this design applicable to NASA programs such as the Crew Exploration Vehicle (CEV).