Abstract: A representative spacecraft system includes a connecting device, which in turn includes a housing having a common port opening, a first connecting element carried by the housing and positioned to connect with a corresponding first spacecraft connecting structure having a first configuration, and a second connecting element carried by the housing and positioned to connect with a corresponding second spacecraft connecting structure having a second configuration different than the first configuration. At least one of the first and second connecting elements is moveable relative to the other between an operational position and a non-operational position, and each of the first and second connecting elements, when connected to the corresponding first or second spacecraft connecting structure, is positioned to allow transport through the common port opening.

Abstract: A variable flow area injector for a liquid rocket engine. The injector has a poppet with a variable outer width portion and a housing with a variable inner width portion. An annular flow path is defined between the variable width portions. Increased throttling of the engine passively increases the annular flow area of the injector by forcing the poppet in a distal direction. Decreased throttling allows a restoring spring to move the poppet in a proximal direction to decrease the annular flow area. A bellows can be included to dampen movement of the poppet. The bellows may be in a propellant-filled cavity separate from the main propellant flow path and have a series of openings through which the separate propellant flows.

Abstract: Rocket components having internal heat fins are described herein. The disclosed components have internal heat fins that mitigate buckling and uneven force application by adding thermal capacity to the component without adding component stiffness. This reduces a thermal force fight (i.e., tension versus compression between cold and hot areas, respectively), which inhibits the buckling loads on the propellant tank. The internal heats fins also provide for a reduced mass of the propellant tank wall relative to a propellant tank wall without internal heat fins. By reducing the thermal force fight, as discussed above, less material can be used which further allows for thinner welds to be used (i.e., less welding material).

Abstract: The present technology is directed to thrusting rails for launch vehicles, and associated systems and methods. Certain embodiments of the thrusting rails can include a first rail housing portion having a cavity and a second rail housing portion having a projection positioned at least partially within the cavity. The rails can include a bellows positioned within the cavity and an elongated tube positioned within the bellows. The elongated tube can include a vent opening in a lateral wall of the elongated tube. A shield can be positioned between the vent opening at the bellows and a sleeve can be positioned within the elongated tube. The sleeve can be constructed from a fibrous material and positioned to retain an ordnance within the elongated tube.

Abstract: Disclosed embodiments include ball valves with an asymmetric seal and seat, to minimize seal wear. In embodiments, a seal is disposed upon a ball with a first and second section, where the first section of the seal is disposed at a different angle from the second section. A seat has a first and second section at different angles that correspond to angles of the first and second section of the seal, respectively, such that the seal fully contacts the seat when the ball is in a closed position. When the ball is rotated to an open position, the different angles of the first and second sections allow the second section of the seal to clear the first section of the seat without contact.

Abstract: Systems and methods for nuclear reactor direct drive of a cryocooler turbine. A nuclear thermal propulsion (NTP) system may have a nuclear reactor that heats a thermal working fluid for directly driving the turbine to power a cryogenic fluid management (CFM) system for keeping propellant at cryogenic temperatures. The features may be used on NTP rockets. The propellant may be liquid hydrogen.

Abstract: A gimbal assembly for a flexible conduit configured to convey a medium is disclosed herein. The gimbal assembly includes a first component including a first plurality of struts that terminate in a first socket defining a first cavity of a first geometric configuration. The gimbal assembly also includes a second component including a second plurality of struts that terminate in a second socket defining a second cavity of a second geometric configuration. A joint fastener is configured to couple the first socket to the second socket. The joint fastener includes a first portion that geometrically corresponds to the first cavity and a second portion that geometrically corresponds to the second cavity. The first portion is configured to be immovably seated within the first cavity, and the second portion is configured to be movably retained by the second socket such that the first component can rotate relative to the second component.

Abstract: A representative spacecraft system includes a launch vehicle elongated along a launch vehicle axis and having at least one stage carrying a corresponding rocket engine. The representative system further includes an annular support structure carried by the at least one stage and positioned to support a cargo spacecraft having a service module and a cargo module. The cargo module of the cargo spacecraft is positioned along the launch vehicle axis in a direction distal from the support structure, and at least a portion of the service module of the cargo spacecraft positioned within an annulus of the support structure.

Abstract: Systems and methods for equalizing fluid levels within a vent line and a propellant tank in which the vent line is located are discussed herein. The vent line includes a vent valve and an equalization valve. The vent valve can be included in a vent duct of the vent line. The equalization valve is included in a bottom wall (i.e., a low point) of the vent duct of the vent line. A controller is also included in the system to instruct a vent valve and the equalization valve to open and close.

Abstract: A representative fault-tolerant rotating electromechanical actuator comprises a permanent magnet synchronous motor with first and second windings that each comprise three phases. First and second voltage source inverters (VSI) provide output signals independently with respect to each other. The first VSI provides output signals to drive the three phases of the first winding, and the second VSI provides output signals to drive the three phases of the second winding. The three phases of the first winding are driven simultaneously with the three phases of the second winding. Control electronics monitor signals associated with the three phases of the windings and detect a fault condition within a first phase of the first winding. The control electronics command the first VSI to drive only second and third phases of the first winding while simultaneously commanding the second VSI to drive the three phases of the second winding.

Abstract: Systems and methods for a fully reusable upper stage for a multi-stage launch vehicle are provided. The reusable upper stage uses an aerospike engine for main propulsion and for vertical landing. A heat shield can include a plurality of scarfed nozzles embedded radially around a semi-spherical surface of the heat shield, wherein inboard surfaces of the plurality of scarfed nozzles collectively define an aerospike contour. The heat shield can be actively cooled to dissipate heat encountered during reentry of the upper stage.

Abstract: Embodiments disclosed herein include fastener assemblies. In an embodiment, a fastener assembly comprises a sleeve with a hole, an inner surface, and top and bottom ends. The top end has a planar surface, and the inner surface has a cylindrical surface. The fastener assembly includes a fastener downwardly extending through the hole, and having a drive slot, a head, a shank, and a threaded region. The head is positioned within the bottom end. The head is separated from the threaded region by the shank. The fastener assembly comprises a cover disposed on the top end and having an access hole and top and bottom surfaces. The cover is welded to the sleeve to define an inner cavity between the cover, sleeve, and fastener head. The access hole is positioned over the drive slot. The cover, sleeve, and fastener comprises materials having high temperature, strength and oxidation resistances.

Abstract: Systems and methods for controlling additive manufacturing processes are disclosed. The systems can include multiple laser directors, soot-removal devices, magnetic chucks, replenishable powder distribution blades, automated powder level detectors, and/or overall process automation techniques.

Abstract: Stud-propelling mechanisms for securing a launch vehicle to a landing platform, and associated systems and methods, are disclosed. A representative system includes a fastening mechanism carried by a landing support element of a portion of a launch vehicle, the mechanism configured to fasten the landing support element to the landing surface when the launch vehicle portion is on the landing surface. The fastening mechanism can include a barrel structure for propelling a stud and an interference portion positioned to receive the stud upon activation of an energetic material that propels the stud. The stud can bind in the interference portion and in the landing surface to fasten the landing support element to the landing surface. A representative method includes automatically fastening a portion of a launch vehicle to a landing surface using a stud carried by the portion of the launch vehicle.

Abstract: Quick disconnect devices for high pressure fluid transfer, and associated systems and methods are disclosed. A representative quick disconnect system includes a first connector and a second connector. The second connector can have an opening sized and shaped to receive a first end of the first connector. The second connector can include a poppet positioned to open the first connector when the first connector is connected to the second connector. The second connector can include an inner sleeve moveable between a first position wherein the poppet head forms a fluid-tight seal with the annular seat of the inner sleeve, and a second position wherein the second end portion is open to permit fluid flow through the end portion of the inner sleeve. In some embodiments, the inner sleeve is pressure balanced in every direction.

Abstract: A gimbal assembly for a flexible conduit configured to convey a medium. The gimbal assembly includes a first component including a first plurality of struts that terminate in a first socket defining a first cavity of a first geometric configuration. The gimbal assembly also includes a second component including a second plurality of struts that terminate in a second socket defining a second cavity of a second geometric configuration. A joint fastener is configured to couple the first socket to the second socket. The joint fastener includes a first portion that geometrically corresponds to the first cavity and a second portion that geometrically corresponds to the second cavity. The first portion is configured to be immovably seated within the first cavity, and the second portion is configured to be movably retained by the second socket such that the first component can rotate relative to the second component.

Abstract: Systems and methods for bonding objects using energetic welding are disclosed. A representative system includes a launch vehicle portion, one or more landing support elements positioned to support the launch vehicle portion when the launch vehicle portion lands on a landing surface, and a bonding device carried by at least one of the landing support elements and configured to form a bond between the bonding device and the landing surface when the launch vehicle portion is on the landing surface. The bond may include a weld. A further representative system includes a bonding device with an energetic material and an anchor element, wherein activating the energetic material deforms the anchor element onto a landing surface to form a weld between the bonding device and the landing surface. A representative method includes automatically bonding a portion of a launch vehicle to a landing surface in response to landing.

Abstract: A modular damper plug forming a multi-volume acoustic resonator in an acoustic liner of a rocket engine is provided. In one aspect, the damper plug includes a main body including a top surface spaced from a bottom surface by a first height, a left surface spaced from a right surface by a width, and an exterior surface spaced from an interior surface by a length. A chamber within the main body extends along a part of the height, a part of the width, and a part of the length, and communicates with the top surface through an opening. The chamber also communicates with the interior surface through one or more ducts. The main body is sized and shaped to be received in any one of a plurality of cavities in the acoustic liner. The chamber includes an upstream volume of the acoustic resonator, and the one or more ducts communicate with a downstream volume of the acoustic resonator when the damper plug is received in any one of the plurality of cavities.

Abstract: A high pressure engine propulsion system, such as a rocket engine, having improved engine performance is described herein. A liquid propellant, such as liquid oxygen, is paramagnetic. Cavitation bubbles of the liquid propellant can form in an inducer tunnel of a turbopump when the pressure in the turbopump inlet drops below the vapor pressure of the liquid propellant. The turbopump includes a magnetic field source external to the inducer tunnel to generate or provide a steady magnetic field across or through the inducer tunnel. The steady magnetic field interacts with the paramagnetic propellant, thereby reducing or eliminating cavitation bubble growth, causing cavitation bubbles to collapse, retaining cavitation bubbles within the inducer tunnel, the like, or combinations thereof.

Abstract: Composite materials and methods of manufacturing composite materials, such as for use in aerospace parts, are described herein. A representative method for manufacturing a coated composite material structure includes applying a plurality of material layers to a preform structure. The plurality of material layers can include at least one first material layer (including a first matrix precursor), and at least one second material layer (including a second matrix precursor and a coating precursor). The method can also include infusing the preform structure with the first and second matrix precursors and the coating precursor from the plurality of material layers. The method can further include heating the infused preform structure to concurrently form a composite material structure and a coating on at least a portion of the composite material structure.