TUSCALOOSA, Ala. – In a recently awarded project, the Alabama Materials Institute at The University of Alabama will aid the Air Force Research Laboratory in developing technology related to a new satellite propellant. The AFRL-developed Advanced Spacecraft Energetic Non-Toxic propellant, formerly known as AF-M315E, is less toxic and burns hotter than current satellite-based propellants, resulting in greater efficiency.
Fuel efficiency affects the length of a satellite mission and its maneuverability in orbit. Changing these limiting factors could significantly increase the capabilities of satellites. Traditional satellite propellants, such as hydrazine, are highly toxic to humans and the environment, so finding safer alternatives yields a multilayered benefit.
The $6 million ASCENT propellant project will see the University working with federal laboratories and industry partners to fully develop this new technology. The biggest hurdle is both a technical and economical one: the fuel requires a catalyst to burn, and the catalyst currently used is prohibitively expensive.
A Very Precious Metal
The rare metal iridium, which currently costs about $5,000 per ounce, is the catalyst for this new propellant. As the lead partner with the Air Force in this program, The University of Alabama will work to fundamentally understand why iridium works as a catalyst and then find a less costly replacement. This will include computational methods and modeling to identify potential candidates, and then experimental work to test those materials and their interactions.
The UA team will then employ additive manufacturing to enable 3D printing of these new materials.
“With the advancement of technologies like additive manufacturing and machine learning, The University now can bring together manufacturing and materials identification technologies to solve this particular problem,” said Dr. Gregory Thompson, professor of metallurgical and materials engineering and executive director of the AMI.
Thompson is the principal investigator of the interdisciplinary team, which includes Dr. Alyssa Stubbers, research engineer; Dr. Heath Turner, Dr. Tibor Szilvasi and Dr. James Harris from the department of chemical & biological engineering; Dr. Gregory Szulczewski from the department of chemistry and Dr. Josh Bittle from the department of mechanical engineering.
Partnerships that Fuel Research
“This is an exciting opportunity enabled by long-standing partnerships with trusted leaders in the field,” said Dr. Bryan Boudouris, vice president for research and economic development. “Dr. Thompson’s leadership, combined with the entire team’s ability to address critical national security opportunities, is a great example of how industry and government collaborate with experts at The University of Alabama to make impactful science and engineering discoveries.”
Other partners include NASA’s Marshall Space Flight Center, which has laboratories where the propellants can be tested safely; Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, which will help identify appropriate 3D printing technologies; and industrial partner Plasma Processes, LLC to lead industrial translation and workforce development.
“We have had a twenty-year working relationship with The University of Alabama in aerospace materials development. This new program offers the next chapter in that collaboration to implement some of the U.S. Space Force’s goals of responsive space needs for increasing national security,” said Tim McKechnie, president of Plasma Processes.
Global Positioning for UA Aerospace Research
This is the first major interdisciplinary project to fall under the mantle of the Alabama Materials Instituted since it launched in November 2023. The program will support faculty research and through them, learning opportunities for graduate students and infrastructure investment to meet the program’s goals. Eventually it will contribute to the economic engine of the aerospace industry in Alabama.
“Whether we are cognizant of it or not, satellites play an important role in our lives, from GPS on our phones to national security,” Thompson said. Making the new ASCENT propellant more accessible and affordable will yield benefits for national security and industry, far into the future.
The University of Alabama, part of The University of Alabama System, is the state’s flagship university. UA shapes a better world through its teaching, research and service. With a global reputation for excellence, UA provides a forward-thinking environment and over 200 degree programs on a beautiful, student-centered campus. A leader in cutting-edge research, UA advances discovery, creative inquiry and knowledge through more than 30 research centers. As the state’s largest higher education institution, UA drives economic growth in Alabama and beyond.