Orion Propulsion successfully completed the first series of hot-fire tests of a new 100 lbf oxygen-methane thruster module. This effort is in conjunction with a Phase 2 NASA Small Business Innovative Research (SBIR) grant and a space act partnership under NASA’s new Innovative Partnerships Program (IPP). For both of these efforts, Orion is currently developing a 100 lbf oxygen-methane thruster that can operate with both gaseous and liquid propellants.

The purpose of the thruster module project is to design, fabricate, and demonstrate the use of composite cryogenic tanks integrated into a propulsion system that is representative of future mission requirements, such as NASA's Orion Crew Exploration Vehicle, Lunar Lander, and long duration space missions. The system utilizes NASA-provided composite tanks, which have undergone extensive cryogenic testing with multiple cryogenic fluids, including liquid oxygen, liquid nitrogen and liquid helium.

NASA Marshall Space Flight Center’s composite tank expert Tom DeLay said, “ This methane thruster development was a fantastic way to demonstrate system level performance of high performance composite tanks and is a step toward scaling up to a full-size vessel.”

The next step on the thruster module effort is to perform a series of extended storage tests on the cryogenic tanks. Orion and NASA will continue hot-fire testing of the module with gaseous and cryogenic propellants. The system will be operated under the conditions of a pressurized propellant system and under the conditions of saturated propellants operating in a blow-down mode.

"Green and in-situ propellant missions are becoming more apparent as industry's needs and mission objectives are changing, and this thruster module is ideally suited for those missions." says Tim Pickens.

NASA has announced that the Boeing Industry Team was selected as NASA’s Ares I Upper Stage Production partner. Orion Propulsion, a member of the Boeing Industry Team, looks forward to helping Boeing produce reaction control system thrusters and test equipment, tooling and test support services. Orion will also provide design, fabrication and testing expertise to the Boeing team. In addition, Orion will provide small-solid team leadership and producibility support.

Orion Propulsion is very pleased at being selected to support the Boeing team and the NASA customer. “Orion has a proven track record of designing, fabricating, and testing aerospace hardware for MSFC. We are excited to continue to support NASA and to be part of the U.S. Space Exploration Program. The Boeing team has shown a real commitment to pursuing lean, affordable manufacturing practices and we are thrilled to be part of that team.” says Orion’s President, Tim Pickens. “They’ve also shown a real commitment to small businesses, and we are pleased about being part of their mentor-protégé program. We see a lot of potential to grow as a supplier to Boeing and NASA. It’s a real pleasure to see rockets being built in the Rocket City of Huntsville.”

Orion Propulsion, Inc. signed an exclusive licensing agreement with ValveTech, Inc. to test, manufacture, and sell monopropellant hydrazine thrusters. This long-life thruster design has flight heritage with the SAC-C and SAOCOM satellites for CONAE. It produces 0.35 pounds-force (lbf) of thrust at a chamber pressure of 400 pounds per square inch absolute (psia). The catalyst bed is packed with S-405 catalyst.

Orion plans to market this thruster to the U.S. military and commercial satellite markets.