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At least 181 records · Page 10

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NASA NTRS1996

A Passive Cavity Concept for Improving the Off-Design Performance of Fixed-Geometry Exhaust Nozzles

An investigation was conducted in the model preparation area of the Langley 16-Foot Transonic Tunnel to study a passive cavity concept for improving the off-design performance of fixed-geometry exhaust nozzles. Passive cavity ventilation (through a porous surface) was applied to divergent flap surfaces and tested at static conditions in a sub-scale, nonaxisymmetric, convergent-divergent nozzle. As part of a comprehensive investigation, force, moment and pressure measurements were taken and focusing schlieren flow visualization was obtained for a baseline configuration and D passive cavity configurations. All tests were conducted with no external flow and high-pressure air was used to simulate jet-exhaust flow at nozzle pressure ratios from 1.25 to approximately 9.50. Results indicate that baseline nozzle performance was dominated by unstable shock-induced boundary-layer separation at off-design conditions, which came about through the natural tendency of overexpanded exhaust flow to satisfy conservation requirements by detaching from the nozzle divergent flaps. Passive cavity ventilation added the ability to control off-design separation in the nozzle by either alleviating separation or encouraging stable separation of the exhaust flow. Separation alleviation offers potential for installed nozzle performance benefits by reducing drag at forward flight speeds, even though it may reduce off-design static thrust efficiency as much as 3.2 percent. Encouraging stable separation of the exhaust flow offers significant performance improvements at static, low NPR and low Mach number flight conditions by improving off-design static thrust efficiency as much as 2.8 percent. By designing a fixed-geometry nozzle with fully porous divergent flaps, where both cavity location and percent open porosity of the flaps could be varied, passive flow control would make it possible to improve off-design nozzle performance across a wide operating range. In addition, the ability to encourage separation on one flap while alleviating it on the other makes it possible to generate thrust vectoring in the nozzle through passive flow control.

Asbury, Scott C.↗

NASA NTRS1996

Application of Optimization Techniques to Design of Unconventional Rocket Nozzle Configurations

Several current rocket engine concepts such as the bell-annular tri-propellant engine, and the linear aerospike being proposed for the X-33 require unconventional three dimensional rocket nozzles which must conform to rectangular or sector shaped envelopes to meet integration constraints. These types of nozzles exist outside the current experience database, therefore, the application of efficient design methods for these propulsion concepts is critical to the success of launch vehicle programs. The objective of this work is to optimize several different nozzle configurations, including two- and three-dimensional geometries. Methodology includes coupling computational fluid dynamic (CFD) analysis to genetic algorithms and Taguchi methods as well as implementation of a streamline tracing technique. Results of applications are shown for several geometeries including: three dimensional thruster nozzles with round or super elliptic throats and rectangualar exits, two- and three-dimensional thrusters installed within a bell nozzle, and three dimensional thrusters with round throats and sector shaped exits. Due to the novel designs considered for this study, there is little experience which can be used to guide the effort and limit the design space. With a nearly infinite parameter space to explore, simple parametric design studies cannot possibly search the entire design space within the time frame required to impact the design cycle. For this reason, robust and efficient optimization methods are required to explore and exploit the design space to achieve high performance engine designs. Five case studies which examine the application of various techniques in the engineering environment are presented in this paper.

Follett, W.↗

NASA NTRS2004

Experimental, Theoretical, and Computational Investigation of Separated Nozzle Flows

A detailed experimental, theoretical, and computational study of separated nozzle flows has been conducted. Experimental testing was performed at the NASA Langley 16-Foot Transonic Tunnel Complex. As part of a comprehensive static performance investigation, force, moment, and pressure measurements were made and schlieren flow visualization was obtained for a sub-scale, non-axisymmetric, two-dimensional, convergent- divergent nozzle. In addition, two-dimensional numerical simulations were run using the computational fluid dynamics code PAB3D with two-equation turbulence closure and algebraic Reynolds stress modeling. For reference, experimental and computational results were compared with theoretical predictions based on one-dimensional gas dynamics and an approximate integral momentum boundary layer method. Experimental results from this study indicate that off-design overexpanded nozzle flow was dominated by shock induced boundary layer separation, which was divided into two distinct flow regimes; three- dimensional separation with partial reattachment, and fully detached two-dimensional separation. The test nozzle was observed to go through a marked transition in passing from one regime to the other. In all cases, separation provided a significant increase in static thrust efficiency compared to the ideal prediction. Results indicate that with controlled separation, the entire overexpanded range of nozzle performance would be within 10% of the peak thrust efficiency. By offering savings in weight and complexity over a conventional mechanical exhaust system, this may allow a fixed geometry nozzle to cover an entire flight envelope. The computational simulation was in excellent agreement with experimental data over most of the test range, and did a good job of modeling internal flow and thrust performance. An exception occurred at low nozzle pressure ratios, where the two-dimensional computational model was inconsistent with the three-dimensional separation observed in the experiment. In general, the computation captured the physics of the shock boundary layer interaction and shock induced boundary layer separation in the nozzle, though there were some differences in shock structure compared to experiment. Though minor, these differences could be important for studies involving flow control or thrust vectoring of separated nozzles. Combined with other observations, this indicates that more detailed, three-dimensional computational modeling needs to be conducted to more realistically simulate shock-separated nozzle flows.

Hunter, Craig A.↗

NASA NTRS1993

Test results from a simple, low-cost, pressure-fed liquid hydrogen/liquid oxygen rocket combustor

A simple, low-cost rocket engine was designed, fabricated, and successfully hot fire tested over a wide range of interface conditions and operating parameters. The engine used low enthalpy hydrogen (45 to 70 R, 200 to 390 psia) and oxygen (139 to 163 R, 210 to 480 psia) propellants pressure-fed directly from facility cryogenic tanks. The engine demonstrated excellent performance, with 97% average combustion efficiency, and absence of combustion instabilities. Engine design chamber pressure was 300 psia, yielding about 16,500 pounds thrust at sea level with a 3:1 expansion ration test nozzle. The engine used a fixed-element injector based on TRW's unique coaxial pintle design, but was operated at 60%, 80%, and 100% thrust levels by throttling facility propellant valves. The engine was tested at propellant mixture ratios (O/F) from 5.8 to 8.4; design O/F was 6.6. To document combustion stability, in five tests RDX explosive pulse guns were detonated in radial and tangential directions across the combustion chamber during steady-state operation. The largest disturbance consisted of simultaneous detonation of a 20-grain radial gun and a 40-grain tangential gun. In no case was an instability, either feed system mode or chamber acoustic mode, excited. High-frequency piezoelectric pressure transducers documented stable recovery from disturbance overpressures within 40 milliseconds of peak pressure. A total of 67 firing tests, accumulating 149 seconds of firing time above 10% P(sub c), were performed. Since parametric testing required run durations of only 2 to 3 seconds, a heat sink combustion chamber was employed for most runs. To evaluate the feasibility of a low-cost ablative system for a flight engine design, one 20-second continuous firing was conducted with a silicone rubber chamber/throat/nozzle liner cast in one piece directly into the engine. The ablative engine operated at the equivalent of 309 seconds sea level specific impulse, when adjusted to a 98% efficient 6:1 expansion ration nozzle, and 430 seconds vacuum specific impulse, when adjusted to a 98% efficient 50:1 expansion ratio nozzle. This engine and test series represent an initial subscale demonstration of a new booster-class engine that eliminates the cost and complexity associated with regenerative cooling and typical engine cycles. This paper presents a description of the engine design and discussion and summary data plots of the performance measured during the parametric testing.

Dressler, G. A.↗

NASA NTRS1947

Investigation of Single-Stage Modified Turbine of Mark 25 Torpedo Power Plant

Efficiency investigations have been made on a single-stage modification of the turbine of a Mark 25 aerial torpedo to determine the performance of the unit with five different turbine nozzles. The output of the turbine blades was computed by analyzing the windage and mechanical-friction losses of the unit. The turbine was faund to be most efficient with a cast nozzle having sharp-edged inlets to the nine nozzle ports. An analysis af the effectiveness af the first and second stages of the standard Mark 25 torpedo turbine indicates that the first- stage turbine contributes nearly all the brake power produced at blade-jet speed ratios above 0.26.

Hoyt, Jack W.↗

DOE OSTI2020

Ultracompact 3D microfluidics for time-resolved structural biology

To advance microfluidic integration, we present the use of two-photon additive manufacturing to fold 2D channel layouts into compact free-form 3D fluidic circuits with nanometer precision. We demonstrate this technique by tailoring microfluidic nozzles and mixers for time-resolved structural biology at X-ray free-electron lasers (XFELs). We achieve submicron jets with speeds exceeding 160 ms -1 , which allows for the use of megahertz XFEL repetition rates. By integrating an additional orifice, we implement a low consumption flow-focusing nozzle, which is validated by solving a hemoglobin structure. Also, aberration-free in operando X-ray microtomography is introduced to study efficient equivolumetric millisecond mixing in channels with 3D features integrated into the nozzle. Such devices can be printed in minutes by locally adjusting print resolution during fabrication. This technology has the potential to permit ultracompact devices and performance improvements through 3D flow optimization in all fields of microfluidic engineering.

3-D reconstruction↗

NASA NTRS1987

The design and operating characteristics of an advanced 30-kW ammonia arcjet engine

Experimental investigations were conducted to evaluate the effects of a contoured nozzle and modified cathode shape on ammonia arcjet engine performance. The contoured nozzle performance data were compared to the performance data of an arcjet which had a 38-deg included-angle, conical nozzle. Thrust improvements of up to 10 percent were demonstrated which corresponded to 3 percent improvements in specific impulse and 10 percent improvements in thrust efficiency. Performance characterizations for the modified cathode tip were conducted with the contoured nozzle arcjet. A uniform 15 percent decrease in arc voltage was demonstrated over a mass flow range of 0.175 to 0.350 g/s. A 4 percent improvement in thrust efficiency was noted at 22.0 kW.

Deininger, William D.↗

DOE OSTI2024

Development of prechamber enabled mixing-controlled combustion strategy for ultra-low methane emissions from lean burn natural gas engines

This numerical study explores the optimization of Prechamber Enabled Mixing-Controlled Combustion (PC-MCC) using natural gas in heavy-duty engines, aiming to enhance combustion efficiency to minimize methane slip and NOx emissions. The approach involves a prechamber ignition system, distinct from conventional spark ignition (SI) systems, to initiate combustion of direct injected natural gas. By leveraging the robust ignition characteristics of the prechamber, the PC-MCC method demonstrates significant potential in achieving efficient combustion akin to diesel engines but with lower greenhouse gas emissions. The research evaluates the effects of various geometric and operational parameters on the combustion process and emissions, including prechamber volume, nozzle diameter, direct injector (DI) geometry, and engine operating strategies. Computational Fluid Dynamics (CFD) simulations are utilized, focusing on a heavy-duty, single-cylinder engine modeled after the Caterpillar C9.3B engine. Key findings indicate that a prechamber volume of 3 cc, coupled with a nozzle diameter of 2.75 mm for two prechamber holes, strikes an optimal balance between combustion efficiency and emissions reduction. This configuration ensures robust combustion across a range of operating conditions while maintaining methane slip within targeted limits. Further investigation into DI geometry shows the significance of the injector umbrella angle and nozzle diameter in shaping the fuel-air mixing and combustion dynamics. An umbrella angle of 130° and a nozzle diameter of 300 microns are identified as optimal, promoting rapid and efficient combustion with minimized methane and NOx emissions. The study also investigates the impact of injection timing and pressure, highlighting their roles in controlling combustion timing and influencing emissions levels. Advanced injection timing is found to be crucial in achieving the desired low methane slip, whereas retarded injection timing assists to reduce NOx emissions while having a slight increase in methane emissions. Operating strategies incorporating various levels of Exhaust Gas Recirculation (EGR) are assessed for their effectiveness in further reducing emissions. The research demonstrates that a judicious combination of internal hot EGR and careful calibration of DI pressure and SOI timing can achieve significant reductions in NOx emissions while keeping methane slip under control. Specifically, an internal EGR level of 15%–25%, combined with DI pressures of 200–300 bar and injection timings at or after top dead center, is recommended. These findings contribute valuable insights into the development of advanced combustion techniques for natural gas engines, offering a viable pathway to reduce methane slip without compromising engine efficiency or performance. The PC-MCC system presents a promising solution for the future of heavy-duty natural gas engine technology to reduce methane emissions.

Nsaif, Osama↗

DOE OSTI2024

A Simulated Evaluation of Powder Flowability Through a Partially Obstructed Consumable in Blown Powder Directed Energy Deposition Systems

Abstract In the interest of continued industrialization of metal additive manufacturing in modern production environments, cost is often referenced as a primary deterrent to new adopters. Conventional economic models for additive systems, processes, and supply chains often focus on specific process applications with little generalizability, or they neglect significant costs associated with production such as machine maintenance and consumable part replacement. Compounding the latter issue are substantial knowledge gaps in consumable part wear characterization for additive and other convergent manufacturing systems. In coaxial blown powder directed energy deposition systems, gas atomized metal powder is wasted during material deposition at a rate that is partly dependent on present wear phenomena in a consumable nozzle housed in the cladding head assembly. The price and lead time required to replace the nozzle incentivizes its reuse even when visibly worn. Often this initiates a process quality decline in the form of underbuilt geometry and internal defects due to losses in powder catchment efficiency. While depositing H13 steel using a hybrid manufacturing machine tool equipped with such a deposition system, a unique partial clog with a bridge-like structure formed at the consumable nozzle exit when supporting argon gas flows failed mid-process. To further understand coaxial multi-phase powder flow in the event of support gas failure, a computational fluid dynamics simulation is tailored to relevant process parameters, H13 powder material profile, and machine operator observations collected after the incident. The resulting differences in powder flow compared to control gas flow parameters is presented and discussed. The powder flowability and performance of the clogged nozzle is then assessed by using an optical profilometer to extract the profile of the clog and recreate the clog geometry within the simulation environment. In past work this simulation has been experimentally validated for a 316L steel powder material profile and used specifically for analyzing powder stream geometry and catchment efficiency. After the initial powder flow characterization, the clog is removed, and the nozzle is reprofiled. After removing the obstructing clog, the newly unobstructed nozzle geometry, the original off the shelf nozzle geometry, and additional nozzle profiles exploring different consumable refurbishment strategies are reevaluated in the simulation. Powder catchment efficiency for all variant nozzle geometries and relevant flow variables are compared and discussed, along with potential mitigation strategies for optimizing powder flowability with worn consumables. This work expands on the known morphology of blown powder obstructions and wear defects present in consumable coaxial nozzles while discussing pragmatic simulation driven responses to unanticipated subsystem failure in hybrid manufacturing machining platforms.

DeWitte, Lisa↗

DOE OSTI2025

Enhancing cold spray coatings: Microstructural dynamics and performance attributes of Inconel 625 with chromium carbide incorporation for hydropower applications

The incorporation of chromium carbide (CrC) particles into the cold spray (CS) process is known to mitigate nozzle clogging, although at the expense of deposition efficiency. This study explores the intricate microstructural changes induced by varying amounts of CrC powder (12.5 % and 6 %) in conjunction with Inconel-625 (Inc-625) powder. The deposition was carried out onto A27 cast steel under different CS parameters. Microstructural characterization, including detailed electron microscopy studies, reveals a complex yet structurally stable coating. Noteworthy features include grain fragmentation and a cellular structure enriched with Nb and Mo, with minimal plastic deformation of CrC in the matrix. The cold-sprayed coatings exhibit a significant (~4 times) increase in microhardness compared to the A27 substrate. Mechanical and cavitation erosion properties were systematically investigated. Coatings subjected to higher particle energy conditions with a gas pressure of 600 psi and gas temperature of 650 °C, demonstrated superior resistance to cavitation erosion. This resistance is attributed to a combination of factors, including microstructural characteristics and porosity. Altogether, the study provides valuable insights into the structural dynamics and performance of CS coatings enriched with CrC particles.

A27 cast steel↗

NASA NTRS1992

High power arcjet

In this period a new mass flow controller was brought into the gas supply system, so that the upper limit for the mass flow rate could be increased up to 500 mg/s with hydrogen. A maximum specific impulse of 1500 s could be achieved with the high powered arcjet (HIPARC) at an efficiency of slightly better than 20 percent. Different nozzle throat diameters had been tested. The 100 kilo-watt input power limit was reached with the 4 mm nozzle throat diameter at a mass flow rate of 400 mg/s. Tests were carried out with different cathode gaps and with three different cathodes. In addition measurements of pressure and gas temperature were taken in the feed line in order to determine the pressure drop in the propellant injectors.

Goelz, T. M.↗

NASA NTRS1995

1025:1 Area Ratio Nozzle Evaluated at High Combustion Chamber Pressure

A recently completed experimental test program obtained performance data on an optimally contoured nozzle with an exit-to-throat area ratio of 1025:1 and on a truncated version of this nozzle with an area ratio of 440:1. The nozzles were tested with gaseous hydrogen and liquid oxygen propellants at combustion chamber pressures of 12.4 to 16.5 mPa (1800 to 2400 psia). Testing was conducted in the altitude test capsule at the NASA Lewis Research Center's Rocket Engine Test Facility (RETF), and results were compared with analytical performance predictions. This testing builds on previous work with this nozzle at Lewis, where testing was completed at nominal chamber pressure of 350 psia. High-area-ratio nozzles have long been sought as a means to increase the performance of spacebased rocket engines. However, as the area ratio increases, the physical size and weight of the nozzle also increase. As a result, engine and vehicle designers must make tradeoffs between nozzle size and performance enhancement. Until this test program, very little experimental data existed on the performance of the high-area-ratio nozzles used in rocket engine designs. The computer codes being used by rocket engine designers rely on data extrapolated from tests of low-area-ratio nozzles, and these extrapolations do not always provide the accuracy needed for a reliable design assessment. Therefore, we conducted this high-area-ratio nozzle testing program to provide performance data for use in rocket engine design and analysis computer codes. The nozzle had a nominal 2.54-cm- (1-in.-) diameter throat, an exit diameter of 81.3-cm (32.0-in.) at an exit-to-throat area ratio of 1025, and a length of 128.6 cm (50.6 in.). Testing was conducted in an altitude test capsule to simulate the static pressure at altitude by vacuum pumping. Data such as propellant mass flow, oxidizer-to-fuel mixture, and thrust were measured. These measurements were then used to calculate performance factors such as the thrust coefficient, the characteristic exhaust velocity efficiency, and the vacuum specific impulse. In addition, the nozzle temperature was measured to calculate the amount of heat transferred from the combustion gases to the nozzle.

Source record↗

NASA NTRS1987

Experimental thrust performance of a high-area-ratio rocket nozzle

An experimental investigation was conducted to determine the thrust performance attainable from high-area-ratio rocket nozzles. A modified Rao-contoured nozzle with an expansion area of 1030 was test fired with hydrogen-oxygen propellants at altitude conditions. The nozzle was also tested as a truncated nozzle, at an expansion area ratio of 428. Thrust coefficient and thrust coefficient efficiency values are presented for each configuration at various propellant mixture ratios (oxygen/fuel). Several procedural techniques were developed permitting improved measurement of nozzle performance. The more significant of these were correcting the thrust for the aneroid effects, determining the effective chamber pressure, and referencing differential pressure transducers to a vacuum reference tank.

Pavli, Albert J.↗

NASA NTRS1986

Experimental thrust performance of a high area-ratio rocket nozzle

Pavli, A. J.↗

NASA NTRS1998

Initial Flight Test Evaluation of the F-15 ACTIVE Axisymmetric Vectoring Nozzle Performance

A full envelope database of a thrust-vectoring axisymmetric nozzle performance for the Pratt & Whitney Pitch/Yaw Balance Beam Nozzle (P/YBBN) is being developed using the F-15 Advanced Control Technology for Integrated Vehicles (ACTIVE) aircraft. At this time, flight research has been completed for steady-state pitch vector angles up to 20' at an altitude of 30,000 ft from low power settings to maximum afterburner power. The nozzle performance database includes vector forces, internal nozzle pressures, and temperatures all of which can be used for regression analysis modeling. The database was used to substantiate a set of nozzle performance data from wind tunnel testing and computational fluid dynamic analyses. Findings from initial flight research at Mach 0.9 and 1.2 are presented in this paper. The results show that vector efficiency is strongly influenced by power setting. A significant discrepancy in nozzle performance has been discovered between predicted and measured results during vectoring.

Orme, John S.↗

NASA NTRS1992

Los Alamos research in nozzle based coaxial plasma thrusters

The topics are presented in viewgraph form and include the following: research approach; perspectives on efficient magnetoplasmadynamic (MPD) operation; NASA and DOE supported research in ideal magnetohydrodynamic plasma acceleration and flow, electrode phenomena, and magnetic nozzles; and future research directions and plans.

Scheuer, Jay↗

NASA NTRS2005

High Speed Civil Transport (HSCT) Isolated Nacelle Transonic Boattail Drag Study and Results Using Computational Fluid Dynamics (CFD)

Nozzle boattail drag is significant for the High Speed Civil Transport (HSCT) and can be as high as 25 percent of the overall propulsion system thrust at transonic conditions. Thus, nozzle boattail drag has the potential to create a thrust drag pinch and can reduce HSCT aircraft aerodynamic efficiencies at transonic operating conditions. In order to accurately predict HSCT performance, it is imperative that nozzle boattail drag be accurately predicted. Previous methods to predict HSCT nozzle boattail drag were suspect in the transonic regime. In addition, previous prediction methods were unable to account for complex nozzle geometry and were not flexible enough for engine cycle trade studies. A computational fluid dynamics (CFD) effort was conducted by NASA and McDonnell Douglas to evaluate the magnitude and characteristics of HSCT nozzle boattail drag at transonic conditions. A team of engineers used various CFD codes and provided consistent, accurate boattail drag coefficient predictions for a family of HSCT nozzle configurations. The CFD results were incorporated into a nozzle drag database that encompassed the entire HSCT flight regime and provided the basis for an accurate and flexible prediction methodology.

Midea, Anthony C.↗

NASA NTRS1999

High Speed Civil Transport (HSCT) Isolated Nacelle Transonic Boattail Drag Study and Results Using Computational Fluid Dynamics (CFD)

Nozzle boattail drag is significant for the High Speed Civil Transport (HSCT) and can be as high as 25% of the overall propulsion system thrust at transonic conditions. Thus, nozzle boattail drag has the potential to create a thrust-drag pinch and can reduce HSCT aircraft aerodynamic efficiencies at transonic operating conditions. In order to accurately predict HSCT performance, it is imperative that nozzle boattail drag be accurately predicted. Previous methods to predict HSCT nozzle boattail drag were suspect in the transonic regime. In addition, previous prediction methods were unable to account for complex nozzle geometry and were not flexible enough for engine cycle trade studies. A computational fluid dynamics (CFD) effort was conducted by NASA and McDonnell Douglas to evaluate the magnitude and characteristics of HSCT nozzle boattail drag at transonic conditions. A team of engineers used various CFD codes and provided consistent, accurate boattail drag coefficient predictions for a family of HSCT nozzle configurations. The CFD results were incorporated into a nozzle drag database that encompassed the entire HSCT flight regime and provided the basis for an accurate and flexible prediction methodology.

Midea, Anthony C.↗