Overview of Acoustic and Sonic Boom Advancements During Development of NASA Launch Vehicles
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Engineering topics
Publications and source records attributed to Kenny, Jeremy.
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As a launch vehicle lifts off the pad, depending on the flyaway maneuver, it will drift away from the exhaust hole causing the plume(s) to impinge on the launch deck. This impingement on the deck creates acoustic sources and causes the noise levels on the vehicle to increase. The percentage of the plume which impinges on the deck can be calculated and related to sound pressure levels. Using this information, a delta dB can be calculated if the drift or flyaway maneuver for a specific vehicle changes during a program
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During liftoff a vehicle can drift due to wind, nozzle gimbaling, fly away maneuver, etc... This drift can cause the exhaust plumes to impinge on the deck and cause the noise levels experienced by the vehicle to increase. A small increase in the plume impingement can have a dramatic effect on the noise levels when the vehicle is only a few nozzle diameters from the deck. As the vehicle lifts off the deck the increase in noise levels lessens as the plume impingement increases. Several scale model acoustic tests have been undertaken at Marshall Space Flight Center which had test cases that were used to define the relationship between drift and the noise levels experienced by the vehicle.
The current vibro-acoustic analysis tools require specific spatial correlation parameters as input to define the liftoff acoustic environment experienced by the launch vehicle. Until recently these parameters have not been very well defined. A comprehensive set of spatial correlation data were obtained during a scale model acoustic test conducted in 2014. From these spatial correlation data, several parameters were calculated: the decay coefficient, the diffuse to propagating ratio, and the angle of incidence. Spatial correlation data were also collected on the EFT-1 flight of the Delta IV vehicle which launched on December 5th, 2014. A comparison of the spatial correlation parameters from full scale and model scale data will be presented.
Injector design is a critical part of the development of a rocket Thrust Chamber Assembly (TCA). Proper detailed injector design can maximize propulsion efficiency while minimizing the potential for failures in the combustion chamber. Traditional design and analysis methods for hydrocarbon-fuel injector elements are based heavily on empirical data and models developed from heritage hardware tests. Using this limited set of data produces challenges when trying to design a new propulsion system where the operating conditions may greatly differ from heritage applications. Time-accurate, Three-Dimensional (3-D) Computational Fluid Dynamics (CFD) modeling of combusting flows inside of injectors has long been a goal of the fluid analysis group at Marshall Space Flight Center (MSFC) and the larger CFD modeling community. CFD simulation can provide insight into the design and function of an injector that cannot be obtained easily through testing or empirical comparisons to existing hardware. However, the traditional finite-rate chemistry modeling approach utilized to simulate combusting flows for complex fuels, such as Rocket Propellant-2 (RP-2), is prohibitively expensive and time consuming even with a large amount of computational resources. MSFC has been working, in partnership with Streamline Numerics, Inc., to develop a computationally efficient, flamelet-based approach for modeling complex combusting flow applications. In this work, a flamelet modeling approach is used to simulate time-accurate, 3-D, combusting flow inside a single Gas Centered Swirl Coaxial (GCSC) injector using the flow solver, Loci-STREAM. CFD simulations were performed for several different injector geometries. Results of the CFD analysis helped guide the design of the injector from an initial concept to a tested prototype. The results of the CFD analysis are compared to data gathered from several hot-fire, single element injector tests performed in the Air Force Research Lab EC-1 test facility located at Edwards Air Force Base.
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Launched from the Mid-Atlantic Regional Spaceport (MARS) Pad 01B on August 22, 2008, the ATK Launch Vehicle (ALV-X1) provided an opportunity to measure liftoff acoustic noise data. Predicted lift-off acoustic environments were developed by both NASA MSFC and ATK engineers. ATK engineers developed predictions for use in determining vibro-acoustic loads using the method described in the monograph NASA SP-8072. The MSFC ALV-X1 lift-off acoustic prediction was made with the Vehicle Acoustic Environment Prediction Program (VAEPP). The VAEPP and SP-8072 methods predict acoustic pressures of rocket systems generally scaled to existing rocket motor data based upon designed motor or engine characteristics. The predicted acoustic pressures are sound-pressure spectra at specific positions on the vehicle. This paper presents the measured liftoff acoustics on the vehicle and tower. This data is useful for the ALV-X1 in validating the pre-launch environments and loads predictions.
The ATK Launch Vehicle (ALV-X1) provided an opportunity to measure liftoff acoustic noise data. NASA Marshall Space Flight Center (MSFC) engineers were interested in the ALV-X1 launch because the First Stage motor and launch pad conditions, including a relativity short deflector ducting, provide a potential analogue to future Ares I launches. This paper presents the measured liftoff acoustics on the vehicle and tower. Those measured results are compared to predictions based upon the method described in NASA SP-8072 "Acoustic Loads Generated by the Propulsion System" and the Vehicle Acoustic Environment Prediction Program (VAEPP) which was developed by MSFC acoustics engineers. One-third octave band sound pressure levels will be presented. This data is useful for the ALV-X1 in validating the pre-launch environments and loads predictions. Additionally, the ALV-X1 liftoff data can be scaled to define liftoff environments for the NASA Constellation program Ares vehicles. Vehicle liftoff noise is caused by the supersonic jet flow interaction with surrounding atmosphere or more simply, jet noise. As the vehicle's First Stage motor is ignited, an acoustic noise field is generated by the exhaust. This noise field persists due to the supersonic jet noise and reflections from the launch pad and tower, then changes as the vehicle begins to liftoff from the launch pad. Depending on launch pad and adjacent tower configurations, the liftoff noise is generally very high near the nozzle exit and decreases rapidly away from the nozzle. The liftoff acoustic time range of interest is typically 0 to 20 seconds after ignition. The exhaust plume thermo-fluid mechanics generates sound at approx.10 Hz to 20 kHz. Liftoff acoustic noise is usually the most severe dynamic environment for a launch vehicle or payload in the mid to high frequency range (approx.50 to 2000 Hz). This noise environment can induce high-level vibrations along the external surfaces of the vehicle and surrounding launch facility structures. The acoustic pressure fluctuations will induce severe vibrations in relatively large lightweight structures. Consequently, there is the potential for failure of the structure or attached electrical components. Due to these potential failures, the liftoff acoustic noise is one of the noise source inputs used to determine the vibro-acoustic qualification environment for a launch vehicle and its components.
Lift-off acoustic environments for NASA's Ares I - Crew Launch Vehicle are predicted using the second source distribution methodology described in the NASA SP-8072. Three modifications made to the model include a shorter core length approximation, a core termination procedure upon plume deflection, and a new set of directivity indices measured from static test firings of the Reusable Solid Rocket Motor (RSRM). The modified sound pressure level predictions increased more than 5 dB overall, and the peak levels shifted two third-octave bands higher in frequency.
Lift-off acoustic environments generated by the future Ares I launch vehicle are assessed by the NASA Marshall Space Flight Center (MSFC) acoustics team using several prediction tools. This acoustic environment is directly caused by the Ares I First Stage booster, powered by the five-segment Reusable Solid Rocket Motor (RSRMV). The RSRMV is a larger-thrust derivative design from the currently used Space Shuttle solid rocket motor, the Reusable Solid Rocket Motor (RSRM). Lift-off acoustics is an integral part of the composite launch vibration environment affecting the Ares launch vehicle and must be assessed to help generate hardware qualification levels and ensure structural integrity of the vehicle during launch and lift-off. Available prediction tools that use free field noise source spectrums as a starting point for generation of lift-off acoustic environments are described in the monograph NASA SP-8072: "Acoustic Loads Generated by the Propulsion System." This monograph uses a reference database for free field noise source spectrums which consist of subscale rocket motor firings, oriented in horizontal static configurations. The phrase "subscale" is appropriate, since the thrust levels of rockets in the reference database are orders of magnitude lower than the current design thrust for the Ares launch family. Thus, extrapolation is needed to extend the various reference curves to match Ares-scale acoustic levels. This extrapolation process yields a subsequent amount of uncertainty added upon the acoustic environment predictions. As the Ares launch vehicle design schedule progresses, it is important to take every opportunity to lower prediction uncertainty and subsequently increase prediction accuracy. Never before in NASA s history has plume acoustics been measured for large scale solid rocket motors. Approximately twice a year, the RSRM prime vendor, ATK Launch Systems, static fires an assembled RSRM motor in a horizontal configuration at their test facility in Utah. The remaining RSRM static firings will take place on elevated terrain, with the nozzle exit plume being mostly undeflected and the landscape allowing placement of microphones within direct line of sight to the exhaust plume. These measurements will help assess the current extrapolation process by direct comparison between subscale and full scale solid rocket motor data.