Firing Up the Future

Delivering Precision Testing for Our Nation’s Space Missions

Propulsion systems present unique challenges when compared to other space system testing. For example, when evaluating guidance, navigation, and control systems, teams can assess most variables and simulate entire launches on a series of avionics computers.

While some aspects of propulsion system testing can be simulated on computers, many variables can only be tested in live exercises that demonstrate how various components perform and react under real launch conditions.

As the space industry continues to evolve, the Department of Defense (DOD), NASA, and commercial providers rely on expert test and evaluation partners who understand the intricacies of various component materials and propellants and can design safe testing protocols to mitigate risk while evaluating emerging fuels that will power tomorrow’s space flights.

Astrion has extensive experience testing and evaluating myriad propulsion fuels and systems for DOD and NASA. We support the Arnold Engineering Development Complex (AEDC) under the Test Operations and Sustainment II contract, where we test and evaluate weapon, propulsion, aerodynamic, and space systems at realistic conditions through modeling, simulation, and ground and flight test facilities across eight states.

Astrion also provides the core hands-on fabrication, assembly, integration, and test capabilities critical to propulsion systems development for NASA Marshall Space Flight Center. For example, we supported the successful pressure test on a sub-scale version of an inflatable habitation module designed for the world’s first commercial space station. We also tested NASA’s Space Launch System liquid hydrogen tank to demonstrate it could withstand more than 260% of forces expected during Artemis lunar missions.

In these propulsion testing programs, we focus on several key factors:

1. How does fuel type affect test design? It’s critical to understand how various fuels and oxidizers work together and how to develop and adjust tests accordingly. When testing a new fuel in development, we must evaluate the various properties or attributes. Are they corrosive? Are they stable? Do they require cryogenics? As we move into subscale testing, can we produce the required thrust? And importantly, as we progress to larger system testing, does our understanding scale?

2. How can we work together to create the most representative environment? To be successful, propulsion testing initiatives must be very collaborative. As our team works with each new entity exploring test capabilities at AEDC, we make sure we have a complete picture of what they are trying to achieve – from the conditions they want to replicate to the performance metrics they want to measure. We work seamlessly across test engineering, facility operations, program management, and our customer teams to create an environment that is as close to the operational environment as possible.

3. How do we protect mission confidentiality and security? Many programs have unique classification requirements. We understand and emphasize who must be involved, who can be involved, and specific requirements for transporting and storing classified materials and systems.

4. How can we take advantage of synergies? While customer information is often proprietary, we look for opportunities to share test infrastructure or lessons learned across programs – saving time and resources without compromising confidentiality.