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Design of a Propeller with Global Minimum Torque

Academia, industry, and Government are actively working towards a future where dozens of small to large Unmanned Aerial Systems (UAS) are present within urban environments. In this environment, high noise pollution and inefficiencies have the potential to render these new technologies impractical due to public annoyance and nonacceptance. This study aims to design and analyze a novel propeller design for minimum global torque using an optimization algorithm to find the full three dimensional solution of maximum efficiency. This resulted in a 𝐶 𝑙 distribution defining the global minimum torque solution for propeller design which corresponded with moving as much lift inboard as possible and reducing lift rapidly at the blade tip. The novel propeller (dubbed "Prandtl" propeller) was then compared with the current gold standard in propeller design, a minimum induced loss (MIL) propeller, which had all the same geometric properties except for blade twist and produced the same amount of thrust at the same advance ratio. The results of multiple iterations of Prandtl propellers showed an increase in efficiency of 2.0-3.3% for the Prandtl blade when compared to the equivalent MIL blade. A potential added benefit of this blade design is lower noise generation due to the lower lift loading at the tip reducing the large shear layer intensity which is the point source of noise in propellers. Two major breakthroughs for enabling widespread use of UAS in urban environments are noise reduction and vehicle efficiency, and this new propeller design has the potential to provide both.

Propeller↗
NASA NTRS1974

Propeller modulation effects on a scanning beam microwave landing system

An investigation to assess the modulation effects on microwave signals transmitted through rotating propeller blades. Interruption of the antenna line-of-sight signal by the rotating propeller causes a variation of path loss, which produces essentially an amplitude modulation of the received signal. This interruption or blockage effect is generally only partial because of edge diffraction around the particular interfering propeller blade. Signals reflected from the rotating propeller will also cause Doppler frequency shifts to be present in the received signals. A scanning beam microwave landing system (MLS) known as MODILS (modular instrument landing system) was used to process the received signals for display. The effects of propeller modulation were studied by varying the following parameters: (1) spacing between propeller and receiving antenna, (2) propeller dimensions, (3) propeller speed (rpm), (4) number of propeller blades, (5) system data rate, (6) receiver response time, and (7) receiver antenna aperture.

Pope, J. M.↗
NASA NTRS1983

Prediction of a propellant tank pressure history using state space methods

An analysis of the time response of a propellant supply system operating in the blowdown mode is presented. The supply system is part of a pump-fed propulsion system intended for use on interplanetary spacecraft. As such, the supply system must provide the pump with propellant at sufficient pressure to avoid pump cavitation. The system, consisting of the tank, the liquid propellant, the pressurant gas and propellant vapor mixture, and a film layer separating the liquid and vapor phases, is analyzed using the principles of mass and energy conservation. The resulting set of ordinary, coupled, nonlinear differential equations for the thermodynamic state variables is integrated as an initial value problem. The resulting histories of total pressure, propellant vapor pressure, propellant liquid temperature, film layer temperature, propellant vapor/pressurant gas temperature, propellant vapor mass, and propellant liquid mass enable the calculation of the net positive suction head available at the pump which determines the viability of the pump-fed system concept when operated in the blowdown mode.

Estey, P. N.↗
NASA NTRS1986

Low-speed wind-tunnel tests of single- and counter-rotation propellers

A low-speed (Mach 0 to 0.3) wind-tunnel investigation was conducted to determine the basic performance, force and moment characteristics, and flow-field velocities of single- and counter-rotation propellers. Compared with the eight-blade single-rotation propeller, a four- by four- (4 x 4) blade counter-rotation propeller with the same blade design produced substantially higher thrust coefficients for the same blade angles and advance ratios. The results further indicated that ingestion of the wake from a supporting pylon for a pusher configuration produced no significant change in the propeller thrust performance for either the single- or counter-rotation propellers. A two-component laser velocimeter (LV) system was used to make detailed measurements of the propeller flow fields. Results show increasing slipstream velocities with increasing blade angle and decreasing advance ratio. Flow-field measurements for the counter-rotation propeller show that the rear propeller turned the flow in the opposite direction from the front propeller and, therefore, could eliminate the swirl component of velocity, as would be expected.

Dunham, D. M.↗
NASA NTRS1986

Directivity and trends of noise generated by a propeller in a wake

An experimental study of the effects on far-field propeller noise of a pylon wake interaction was conducted with a scale model of a single-rotation propeller in a low-speed anechoic wind tunnel. A detailed mapping of the noise directivity was obtained at 10 test conditions covering a wide range of propeller power landings at several subsonic tip speeds. Two types of noise penalties were investigated-pulser and spacing. The pusher noise penalty is the difference in the average overall sound pressure level, OASPL, for pusher and tractor installations. (In a pusher installation, the propeller disk is downstream of a pylon or another aerodynamic surface.) The spacing noise penalty is the difference in the average OASPL for different distances between the pylon trailing edge and the propeller. The variations of these noise penalties with axial, or flyover, angle theta and circumferential angle phi are presented, and the trends in these noise penalties with tip Mach number and power loading are given for selected values of theta and phi. The circumferential directivity of the noise from a pusher installation showed that the addition noise due to the interaction of the pylon wake with the propeller had a broad peak over a wide range of circumferential angles approximately perpendicular to the pylon with a sharp minimum 90 deg. to the pylon for the majority of cases tested. The variation of the pusher noise penalty with theta had a minimum occurring near the propeller plane and maximum values of as much as 20 dB occurring toward the propeller axes. The magnitude of the pusher noise penalty generally decreased as propeller tip Mach number or power loading was increased.

Block, P. J. W.↗
NASA NTRS1987

Noise of a model high speed counterrotation propeller at simulated takeoff/approach conditions (F7/A7)

A high speed advanced counterrotation propeller, was tested in the NASA-Lewis 9 x 15 foot Anechoic Wind Tunnel at simulated takeoff/approach conditions of 0.2 Mach number. Acoustic measurements were taken with fixed floor microphones, an axially translating microphone probe, and with a polar microphone probe which was fixed to the propeller nacelle and could take both sideline and circumferential acoustic surveys. Aerodynamic measurements were also made to establish the propeller operating conditions. The propeller was run over a range of blade setting angles from 36.4/36.5 to 41.1/39.4 deg, tip speeds from 165 to 259 m/sec, rotor spacings from 1.56 to 3.63 based on forward rotor tip chord to aerodynamic separation, and angles of attack to + or - 16 deg. First order rotor alone tones showed highest directivity levels near the propeller plane, while interaction tone showed high levels throughout sideline directivity, especially toward the propeller rotation axis. Interaction tone levels were sensitive to propeller row spacing while rotor alone tones showed little spacing effect. There is a decreased noise level associated with higher propeller blade numbers for the same overall propeller thrust.

Woodward, Richard P.↗
NASA NTRS1987

Analytical determination of propeller performance degradation due to ice accretion

A computer code capable of computing the propeller performance for clean, glaze, or rime ice propeller configurations to determine the performance degradation resulting from a given icing encounter has been developed. The inviscid, incompressible flowfield at each specified propeller radial location is first computed using the Theodorsen method. A droplet trajectory computation then calculates the droplet impingement points and airfoil collection efficiency for each radial location. User-selectable empirical correlations are available for determining the aerodynamic penalties due to ice accretion. Propeller performance is finally computed using strip analysis for either the clean or iced propeller. In the iced mode, the thrust and torque coefficient equations are modified by the drag and lift coefficient increments due to ice to obtain the appropriate iced values. Comparison with available experimental propeller icing data shows generally good agreement. The code's capability of properly predicting the thrust coefficient, power coefficient, and propeller efficiency of an iced propeller is shown to be dependent on the choice of empirical correlation employed as well as on the proper specification of the radial icing extent and propeller blade angle.

Miller, T. L.↗
NASA NTRS1987

Noise of a model high speed counterrotation propeller at simulated takeoff/approach conditions (F7/A7)

A high speed advanced counterrotation propeller, was tested in the NASA-Lewis 9 x 15 foot Anechoic Wind Tunnel at simulated takeoff/approach conditions of 0.2 Mach number. Acoustic measurements were taken with fixed floor microphones, an axially translating microphone probe, and with a polar microphone probe which was fixed to the propeller nacelle and could take both sideline and circumferential acoustic surveys. Aerodynamic measurements were also made to establish the propeller operating conditions. The propeller was run over a range of blade setting angles from 36.4/36.5 to 41.1/39.4 deg, tip speeds from 165 to 259 m/sec, rotor spacings from 1.56 to 3.63 based on forward rotor tip chord to aerodynamic separation, and angles of attack to + or - 16 deg. First order rotor alone tones showed highest directivity levels near the propeller plane, while interaction tone showed high levels throughout sideline directivity, especially toward the propeller rotation axis. Interaction tone levels were sensitive to propeller row spacing while rotor alone tones showed little spacing effect. There is a decreased noise level associated with higher propeller blade numbers for the same overall propeller thrust.

Woodward, Richard P.↗
NASA NTRS1988

An analysis for high speed propeller-nacelle aerodynamic performance prediction. Volume 1: Theory and application

A computer program, the Propeller Nacelle Aerodynamic Performance Prediction Analysis (PANPER), was developed for the prediction and analysis of the performance and airflow of propeller-nacelle configurations operating over a forward speed range inclusive of high speed flight typical of recent propfan designs. A propeller lifting line, wake program was combined with a compressible, viscous center body interaction program, originally developed for diffusers, to compute the propeller-nacelle flow field, blade loading distribution, propeller performance, and the nacelle forebody pressure and viscous drag distributions. The computer analysis is applicable to single and coaxial counterrotating propellers. The blade geometries can include spanwise variations in sweep, droop, taper, thickness, and airfoil section type. In the coaxial mode of operation the analysis can treat both equal and unequal blade number and rotational speeds on the propeller disks. The nacelle portion of the analysis can treat both free air and tunnel wall configurations including wall bleed. The analysis was applied to many different sets of flight conditions using selected aerodynamic modeling options. The influence of different propeller nacelle-tunnel wall configurations was studied. Comparisons with available test data for both single and coaxial propeller configurations are presented along with a discussion of the results.

Egolf, T. Alan↗
NASA NTRS1991

Design issues for propulsion systems using metallized propellants

Metallized propellants are liquid propellants that contain metal particles. These particles are suspended in a gelled fuel or oxidizer. Aluminum is used as the metal additive. The addition of metal to conventional propellants can increase their specific impulse and their density over conventional propellants, and consequently, the payload delivered on Mars and lunar transportation vehicles, Earth-to-Orbit vehicles and upper stages for robotic planetary missions. Gelled fuels also provide increased safety during accidental propellant leakage or spills. To take full advantage of these potential performance increases, there are changes that must be made to the vehicle design. The differences are discussed between metallized propellant and traditional liquid propellants and their effect on the propulsion system design. These differences include the propellant density, mixture ratio, engine performance, and propellant rheology. Missions related to the Space Exploration Initiative are considered as design examples to illustrate these issues.

Palaszewski, Bryan↗
NASA NTRS1991

Design issues for propulsion systems using metallized propellants

Metallized propellants are liquid propellants that contain metal particles. These particles are suspended in a gelled fuel or oxidizer. Aluminum is used as the metal additive. The addition of metal to conventional propellants can increase their specific impulse and their density over conventional propellants, and consequently, the payload delivered on Mars and lunar transportation vehicles, Earth-to-Orbit vehicles and upper stages for robotic planetary missions. Gelled fuels also provide increased safety during accidental propellant leakage or spills. To take full advantage of these potential performance increases, there are changes that must be made to the vehicle design. The differences are discussed between metallized propellant and traditional liquid propellants and their effect on the propulsion system design. These differences include the propellant density, mixture ratio, engine performance, and propellant rheology. Missions related to the Space Exploration Initiative are considered as design examples to illustrate these issues.

Palaszewski, Bryan↗
NASA NTRS1957

An Investigation of Single- and Dual-Rotation Propellers at Positive and Negative Thrust, and in Combination with an NACA 1-series D-Type Cowling at Mach Numbers up to 0.84

An investigation has been made to determine the aerodynamic characteristics of the NACA 4-(5)(05)-041 four-blade, single-relation propeller and the NACA 4-(5)(05)-037 six- and eight-blade, dual-rotation propellers in combination with various spinners and NACA d-type spinner-cowling combinations at Mach numbers up to 0.84. Propeller force characteristics, local velocity distributions in the propeller planes, inlet pressure recoveries, and static-pressure distributions on the cowling surfaces were measured for a wide range of blade angles, advance ratios, and inlet-velocity ratios. Included are data showing: (a) the effect of extended cylindrical spinners on the characteristics of the single-rotation propeller, (b) the effect of variation of the difference in blade angle setting between the front and rear components of the dual-rotation propellers, (c) the negative- and static-thrust characteristics of the propellers with 1 series spinners, and (d) the effects of ideal- and platform-type propeller-spinner junctures on the pressure-recovery characteristics of the single-rotation propeller-spinner-cowling combination.

Reynolds, Robert M↗
NASA NTRS1996

Computational Modeling of Magnetically Actuated Propellant Orientation

Unlike terrestrial applications where gravity positions liquid at the "bottom" of the tank, the location of liquid propellant in spacecraft tanks is uncertain unless specific actions are taken or special features are built into the tank. Some mission events require knowledge of liquid position prior to a particular action: liquid must be positioned over the tank outlet prior to starting the main engines and must be moved away from the tank vent before vapor can be released overboard to reduce pressure. It may also be desirable to positively position liquid to improve propulsion system performance: moving liquid away from the tank walls will dramatically decrease the rate of heat transfer to the propellant, suppressing the boil-off rate, thereby reducing overall mission propellant requirements. The process of moving propellant to a desired position is referred to as propellant orientation or reorientation. Propulsive reorientation relies on small auxiliary thrusters to accelerate the tank. The inertia of the liquid causes it to collect in the aft-end of the tank if the acceleration is forward. Liquid Acquisition Devices (LAD's) rely on surface tension to hold the liquid within special geometries, (i.e. vanes, wire-mesh channels, start-baskets), to positively position propellants. Both of these technologies add significant weight and complexity to the spacecraft and can be limiting systems for long duration missions. The subject of the present research is an alternate technique for positively positioning liquid within spacecraft propellant tanks: magnetic fields. LOX is paramagnetic (attracted toward a magnet) and LH2 is diamagnetic (repelled from a magnet). Order-of-magnitude analyses, performed in the 1960's to determine required magnet size, concluded that the magnets would be prohibitively massive and this option has remained dormant during the intervening years. Recent advances in high-temperature superconducting materials hold the promise of electromagnets with sufficient performance to support cryogenic propellant management tasks. In late 1992, NASA MSFC began a new investigation in this technology commencing with the design of the Magnetically-Actuated Propellant Orientation (MAPO) experiment. A mixture of ferrofluid and water is used to simulate the paramagnetic properties of LOX and the experiment is being flown on the KC-135 aircraft to provide a reduced gravity environment. The influence of a 0.4 Tesla ring magnet on flow into and out of a subscale Plexiglas tank is being recorded on video tape. The most efficient approach to evaluating the feasibility of MAPO is to compliment the experimental program with development of a computational tool to model the process of interest. The goal of the present research is to develop such a tool. Once confidence in its fidelity is established by comparison to data from the MAPO experiment, it can be used to assist in the design of future experiments and to study the parameter space of the process. Ultimately, it is hoped that the computational model can serve as a design tool for full-scale spacecraft applications.

Hochstein, John I.↗
NASA NTRS1999

Testing of Densified Liquid Hydrogen Stratification in a Scale Model Propellant Tank

Propellant densification has been identified as a critical technology in the development of a single stage to orbit (SSTO) launch vehicle. The densification of cryogenic propellant through sub-cooling allows more propellant to be stored in a given volume. This allows for higher propellant mass fractions than would otherwise be possible with conventional, normal boiling point, cryogenic fluids. One critical step in determining the viability of densified propellant technology for launch vehicles is to perform the sequential process necessary to load a propellant tank with densified propellants. This paper describes a test program that was conducted at NASA to demonstrate the ability to load densified LH2 into a sub-scale propellant rank. This work was done through a collaborative effort between NASA Lewis Research Center and the Lockheed Martin Michoud Space Systems (LMMSS). The tank, is made from composite materials similar to that to be used on X-33, is formed from two lobes with a center seprum. Test results are shown for data that was collected on filling the sub-scale tank with densified liquid hydrogen propellant that was produced at the NASA Plum Brook Station. Data is compared to analytical predictions.

Greene, W. D.↗
NASA NTRS2001

An Assessment of Helium Evolution from Helium-Saturated Propellant Depressurization in Space

Helium evolution from the transfer of helium-saturated propellant in space is quantified to assess its impacts from creating two-phase gas/liquid flow from the supply tank, gas injection into the receiving tank, and liquid discharge from the receiving tank. Propellant transfer takes place between two similar tanks whose maximum storage capacity is approximately 2.55 cubic meters each. The maximum on-orbit propellants transfer capability is 9000 lbm (fuel and oxidizer). The transfer line is approximately 1.27 cm in diameter and 6096 cm in length and comprised of the fluid interconnect system (FICS), the orbiter propellant transfer system (OPTS), and the International Space Station (ISS) propulsion module (ISSPM). The propellant transfer rate begins at approximately 11 liter per minute (lpm) and subsequently drops to approximately 0.5 lpm. The tank nominal operating pressure is approximately 1827 kPa (absolute). The line pressure drops for Monomethy1hydrazine (MMH) and Nitrogen tetroxide (NTO) at 11.3 lpm are approximately 202 kPa and 302 kPa, respectively. The pressure-drop results are based on a single-phase flow. The receiving tank is required to vent from approximately 1827 kPa to a lower pressure to affect propellant transfer. These pressure-drop scenarios cause the helium-saturated propellants to release excess helium. For tank ullage venting, the maximum volumes of helium evolved at tank pressure are approximately 0.5 ft3 for MMH and 2 ft3 for NTO. In microgravity environment, due to lack of body force, the helium evolution from a liquid body acts to propel it, which influences its fluid dynamics. For propellant transfer, the volume fractions of helium evolved at line pressure are 0.1% by volume for MMH and 0.6 % by volume for NTO at 11.3 lpm. The void fraction of helium evolved varies as an approximate second order power function of flow rate.

Nguyen, Bich N.↗
NASA NTRS2002

Computational Predictions of the Performance Wright 'Bent End' Propellers

Computational analysis of two 1911 Wright brothers 'Bent End' wooden propeller reproductions have been performed and compared with experimental test results from the Langley Full Scale Wind Tunnel. The purpose of the analysis was to check the consistency of the experimental results and to validate the reliability of the tests. This report is one part of the project on the propeller performance research of the Wright 'Bent End' propellers, intend to document the Wright brothers' pioneering propeller design contributions. Two computer codes were used in the computational predictions. The FLO-MG Navier-Stokes code is a CFD (Computational Fluid Dynamics) code based on the Navier-Stokes Equations. It is mainly used to compute the lift coefficient and the drag coefficient at specified angles of attack at different radii. Those calculated data are the intermediate results of the computation and a part of the necessary input for the Propeller Design Analysis Code (based on Adkins and Libeck method), which is a propeller design code used to compute the propeller thrust coefficient, the propeller power coefficient and the propeller propulsive efficiency.

Wang, Xiang-Yu↗
NASA NTRS2010

Analytic Modeling of Pressurization and Cryogenic Propellant

An analytic model for pressurization and cryogenic propellant conditions during all mission phases of any liquid rocket based vehicle has been developed and validated. The model assumes the propellant tanks to be divided into five nodes and also implements an empirical correlation for liquid stratification if desired. The five nodes include a tank wall node exposed to ullage gas, an ullage gas node, a saturated propellant vapor node at the liquid-vapor interface, a liquid node, and a tank wall node exposed to liquid. The conservation equations of mass and energy are then applied across all the node boundaries and, with the use of perfect gas assumptions, explicit solutions for ullage and liquid conditions are derived. All fluid properties are updated real time using NIST Refprop.1 Further, mass transfer at the liquid-vapor interface is included in the form of evaporation, bulk boiling of liquid propellant, and condensation given the appropriate conditions for each. Model validation has proven highly successful against previous analytic models and various Saturn era test data and reasonably successful against more recent LH2 tank self pressurization ground test data. Finally, this model has been applied to numerous design iterations for the Altair Lunar Lander, Ares V Core Stage, and Ares V Earth Departure Stage in order to characterize Helium and autogenous pressurant requirements, propellant lost to evaporation and thermodynamic venting to maintain propellant conditions, and non-uniform tank draining in configurations utilizing multiple LH2 or LO2 propellant tanks. In conclusion, this model provides an accurate and efficient means of analyzing multiple design configurations for any cryogenic propellant tank in launch, low-acceleration coast, or in-space maneuvering and supplies the user with pressurization requirements, unusable propellants from evaporation and liquid stratification, and general ullage gas, liquid, and tank wall conditions as functions of time.

Corpening, Jeremy H.↗
NASA NTRS2008

A Practical, Affordable Cryogenic Propellant Depot Based on ULA's Flight Experience

Mankind is embarking on the next step in the journey of human exploration. We are returning to the moon and eventually moving to Mars and beyond. The current Exploration architecture seeks a balance between the need for a robust infrastructure on the lunar surface, and the performance limitations of Ares I and V. The ability to refuel or top-off propellant tanks from orbital propellant depots offers NASA the opportunity to cost effectively and reliably satisfy these opposing requirements. The ability to cache large orbital quantities of propellant is also an enabling capability for missions to Mars and beyond. This paper describes an option for a propellant depot that enables orbital refueling supporting Exploration, national security, science and other space endeavors. This proposed concept is launched using a single EELV medium class rocket and thus does not require any orbital assembly. The propellant depot provides cryogenic propellant storage that utilizes flight proven technologies augmented with technologies currently under development. The propellant depot system, propellant management, flight experience, and key technologies are also discussed. Options for refueling the propellant depot along with an overview of Exploration architecture impacts are also presented.

Kutter, Bernard F.↗