N161-067 TITLE: Novel Materials and Components for New Liquid Monopropellant Propulsion Systems

TECHNOLOGY AREA(S): Materials/Processes, Weapons

ACQUISITION PROGRAM: Ballistic Missile Defense System (BMDS) - Standard Missile 3 (SM-3) ACAT 1

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

OBJECTIVE: Design and develop materials and systems for new ionic liquid monopropellants capable of providing improved safety with full propulsive capabilities. Focus on the design and demonstration of an electrically controlled ionic liquid monopropellant motor comprising the igniter, vessel, valves, and controls is sought.

DESCRIPTION: Hypergolic propulsion systems are the state-of-the-art technology for extreme control of propellant thrust for Divert and Attitude Control System (DACS); however, their use aboard Navy ships and submarines is severely restricted due to their high reactivity, toxicity, and corrosivity. DACS utilizing solid propellants (Solid DACS (SDACS) or Throttleable Divert Attitude Control System (TDACS)) were developed to circumvent the problems surrounding the use of the hypergolic fuels but impose limitations on the performance of the resulting motor. The capability to significantly reduce the size of these small thrusters without the use of highly volatile hypergolic propellant systems can lead to increased payload capacity and simplification of the propulsion system. A propulsion system utilizing an environmentally benign, low vapor pressure, low toxicity ionic propellant along with the necessary system components that utilize the electrochemical nature of these propellants to control their reaction while maintaining or exceeding the performance of the hypergolic systems can be realized and should allow for the reduction and simplification of current DACS systems. This effort will involve the design and construction of an ionic propellant propulsion system that will leverage electrodes and electrical control of the propulsion phenomena while addressing the stability, corrosion and deleterious electrode reactions that can lead to poor system reliability. A systematic effort to evaluate and develop rational "design rules" for the electrodes and other system components should be undertaken using a hydroxylammonium nitrate (HAN)-based propellant as the baseline ionic propellant composition. The focus of the effort will be on the electrode materials selection, system geometry and the safety of propellant. The propellant selection and propulsion system component design should focus on the requirements for a TDACS used on SM-3 Block II.

PHASE I: Perform an analysis and identify notional system geometries, select promising novel materials for the electrodes, and identify material properties that can impact stability, corrosion and deleterious electrode reactions. Using the baseline HAN monopropellant system, perform theoretical calculations that demonstrate the feasibility of the proposed materials and system. Recommend an electrode material and design for further evaluation and scale-up.

PHASE II: Based on Phase I effort, develop and scale-up an ionic propellant system that utilizes electrodes and electrical control of the propulsion phenomena. Develop "design rules" that can be used to evaluate electrode performance in an electrically controlled motor system utilizing a HAN monopropellant. Conduct performance and safety evaluations and ensure that the system maintains the performance of SM-3 Block II TDACS and that the design is capable of meeting the requirements for safety and suitability for service use outlined in STANAG 4170 and JOTP-001.

PHASE III DUAL USE APPLICATIONS: Based on Phase II effort, fabricate a full-scale motor based on the Phase II design and deliver to a Navy test facility for testing to determine its performance and safety. The small business will support the Navy with certifying and qualifying the design for Navy use. When appropriate the small business will focus on scaling up manufacturing capabilities and commercialization plans. At the completion of this phase, the propulsion system will be ready for transition into a new electrically controlled Divert and Attitude Control System (DACS) for use in a missile system such as SM-3. The capability to significantly reduce the size of small engines and thrusters on commercial spacecraft and satellites without the use of highly volatile hypergolic propellant systems can lead to increased payload capacity and simplification of the propulsion system which can lead to their use in devices such as the Draco thrusters in SpaceX Dragon spacecraft.

REFERENCES:

1. Sawka, W., Katzakian, A., and Grix, C., "Solid State Digital Propulsion Cluster Thrusters For Small Satellites Using High Performance Electrically Controlled Extinguishable Solid Propellants", 19th Annual AIAA/USU Conference on Small Satellites, Utah S

2. Lozano, Paulo, "Fully Scalable Porous Metal Electrospray Propulsion", AFRL-OSR-VA-TR-2012-0970, March 20, 2012.

3. Yetter, R., Yang, V., Aksay, I., and Dryer, F., "Meso and Micro Scale Propulsion Concepts for Small Spacecraft - Final Technical Report", AFRL-SR-AR-TR-06-0280, July 28, 2006.

4. Yetter, R., Yang, V., and Aksay, I., "An Integrated Ignition and Combustion System for Liquid Propellant Micro Propulsion - Technical Report", AFOSR Grant # FA9550-06-1-0183, June 26, 2008.

5. Standard NATO Agreement (STANAG) 4170 Rev. 3, Principles and Methodology for the Qualification of Explosive Materials for Military Use, February 4, 2008.

6. Joint Ordnance Test Procedure (JOTP)-001, Allied Ammunition Safety and Suitability for Service Assessment Testing Publication � Guidance, January 8, 2013.

KEYWORDS: Ionic; monopropellant; solid; propulsion; electrical ignition; AF-M315E, Ammonium Dinitramide; ADN; LMP-103S; hydroxyl ammonium nitrate; HAN

TPOC-1: Clifford Bedford

Email: [email protected]

TPOC-2: Matthew Beyard

Email: [email protected]

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