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Coolant-carrying liner for combustion chambers runs cooler and tolerates high-temperature excursions without burning out. Hot gases flowing through core prevented by liner from damaging shell. Concept applicable to such high-temperature chambers as rocket pre-burners, turbojet cans, stationary-turbine combustors, oil burners, and high-pressure chemical reactors.
The Integrated Systems Test of an Airbreathing Rocket (ISTAR) project was a flight demonstration project initiated to advance the state of the art in Rocket Based Combined Cycle (RBCC) propulsion development. The primary objective of the ISTAR project was to develop a reusable air breathing vehicle and enabling technologies. This concept incorporated a RBCC propulsion system to enable the vehicle to be air dropped at Mach 0.7 and accelerated up to Mach 7 flight culminating in a demonstration of hydrocarbon scramjet operation. A series of component experiments was planned to reduce the level of risk and to advance the technology base. This paper summarizes the status of a full scale direct connect combustor experiment with heated endothermic hydrocarbon fuels. This is the first use of the NASA GRC Hypersonic Tunnel facility to support a direct-connect test. The technical and mechanical challenges involved with adapting this facility, previously used only in the free-jet configuration, for use in direct connect mode will be also described.
Wall heat flux measurements in a 1.5 in. diameter circular cross-section rocket chamber for a uni-element shear coaxial injector element operating on gaseous oxygen (GOz)/gaseous hydrogen (GH,) propellants are presented. The wall heat flux measurements were made using arrays of Gardon type heat flux gauges and coaxial thermocouple instrumentation. Wall heat flux measurements were made for two cases. For the first case, GOZ/GHz oxidizer-rich (O/F=l65) and fuel-rich preburners (O/F=1.09) integrated with the main chamber were utilized to provide vitiated hot fuel and oxidizer to the study shear coaxial injector element. For the second case, the preburners were removed and ambient temperature gaseous oxygen/gaseous hydrogen propellants were supplied to the study injector. Experiments were conducted at four chamber pressures of 750, 600, 450 and 300psia for each case. The overall mixture ratio for the preburner case was 6.6, whereas for the ambient propellant case, the mixture ratio was 6.0. Total propellant flow was nominally 0.27-0.29 Ibm/s for the 750 psia case with flowrates scaled down linearly for lower chamber pressures. The axial heat flux profile results for both the preburner and ambient propellant cases show peak heat flux levels a t axial locations between 2.0 and 3.0 in. from the injector face. The maximum heat flux level was about two times greater for the preburner case. This is attributed to the higher injector fuel-to-oxidizer momentum flux ratio that promotes mixing and higher initial propellant temperature for the preburner case which results in a shorter reaction zone. The axial heat flux profiles were also scaled with respect to the chamber pressure to the power 0.8. The results at the four chamber pressures for both cases collapsed to a single profile indicating that at least to first approximation, the basic fluid dynamic structures in the flow field are pressure independent as long as the chamber/njector/nozzle geometry and injection velocities remain the same.
The results of testing an on-line quadrupole gas analyzer system are reported. Gas samples were drawn from the exhaust of a hydrogen-oxygen-nitrogen rocket which simulated the flow composition and dynamics at the combustor exit of a supersonic combustion ramjet engine. System response time of less than 50 milliseconds was demonstrated, with analytical accuracy estimated to be + or - 5 percent. For more complex chemical systems with interfering atom patterns, analysis would be more difficult. A cooled-gas pyrometer probe was evaluated as a total temperature indicator and as the primary mass flow measuring element for the total sample flow rate.
A series of tests were conducted to investigate RBCC performance at ramjet and scramjet conditions. The hardware consisted of a linear strut-rocket manufactured by Aerojet and a dual-mods scramjet combustor. The hardware was tested at NASA Langley Research Center in the Direct Connect Supersonic Combustion Test Facility at Mach 4.0 and 6.5 simulated flight conditions.
An existing Computational Fluid Dynamics code for simulating complex turbulent flows inside a liquid rocket combustion chamber was validated and further developed. The Advanced Rocket Injector/Combustor Code (ARICC) is simplified and validated against benchmark flow situations for laminar and turbulent flows. The numerical method used in ARICC Code is re-examined for incompressible flow calculations. For turbulent flows, both the subgrid and the two equation k-epsilon turbulence models are studied. Cases tested include idealized Burger's equation in complex geometries and boundaries, a laminar pipe flow, a high Reynolds number turbulent flow, and a confined coaxial jet with recirculations. The accuracy of the algorithm is examined by comparing the numerical results with the analytical solutions as well as experimented data with different grid sizes.
Computational Fluid Dynamics (CFD) is becoming an important component of injector design in the rocket industry. Injector designers who use CFD in the design process need to understand the accuracy level of the particular code being used for certain aspects of the design. This paper represents a recent effort to demonstrate the accuracy of two CFD codes to calculate the wall heat flux for a single element injector. The FDNS and Loci- CHEM codes currently in use at NASA Marshall Space Flight Center were evaluated. The test case was a single shear coaxial element with gaseous oxygen and hydrogen in a chamber instrumented with coaxial heat flux gauges on the chamber wall down the axis. The data were taken at Penn State University. Measured wall temperatures were used as boundary conditions for the CFD calculations. Calculations were compared to experimental data at chamber pressures of 300,450 600, and 750 psia. The accuracy level of both codes was assessed.
Crocco's three-dimensional nozzle admittance theory is extended to be applicable when the amplitudes of the combustor and nozzle oscillations increase or decrease with time. An analytical procedure and a computer program for determining nozzle admittance values from the extended theory are presented and used to compute the admittances of a family of liquid-propellant rocket nozzles. The calculated results indicate that the nozzle geometry entrance Mach number and temporal decay coefficient significantly affect the nozzle admittance values. The theoretical predictions are shown to be in good agreement with available experimental data.
CET89 calculates compositions in chemical equilibrium and properties of mixtures of any chemical system for which thermodynamic data available. Provides following options: obtains chemical-equilibrium compositions and corresponding thermodynamic mixture properties for assigned thermodynamic states; calculates dilute-gas transport properties of complex chemical mixtures; obtains Chapman-Jouguet detonation properties for gaseous mixtures; calculates properties of incident and reflected shocks in terms of assigned velocities; and calculates theoretical performance of rocket for both equilibrium and frozen compositions during expansion. Rocket performance based on optional models of finite or infinite area combustor.
Technology was identified which will enable application of hybrid propulsion to manned and unmanned space launch vehicles. Two design concepts are proposed. The first is a hybrid propulsion system using the classical method of regression (classical hybrid) resulting from the flow of oxidizer across a fuel grain surface. The second system uses a self-sustaining gas generator (gas generator hybrid) to produce a fuel rich exhaust that was mixed with oxidizer in a separate combustor. Both systems offer cost and reliability improvement over the existing solid rocket booster and proposed liquid boosters. The designs were evaluated using life cycle cost and reliability. The program consisted of: (1) identification and evaluation of candidate oxidizers and fuels; (2) preliminary evaluation of booster design concepts; (3) preparation of a detailed point design including life cycle costs and reliability analyses; (4) identification of those hybrid specific technologies needing improvement; and (5) preperation of a technology acquisition plan and large scale demonstration plan.
Propellants, chamber materials, and processes for fabrication of small high performance radiation cooled liquid rocket engines were evaluated to determine candidates for eventual demonstration in flight-type thrusters. Both storable and cryogenic propellant systems were considered. The storable propellant systems chosen for further study were nitrogen tetroxide oxidizer with either hydrazine or monomethylhydrazine as fuel. The cryogenic propellants chosen were oxygen with either hydrogen or methane as fuel. Chamber material candidates were chemical vapor deposition (CVD) rhenium protected from oxidation by CVD iridium for the chamber hot section, and film cooled wrought platinum-rhodium or regeneratively cooled stainless steel for the front end section exposed to partially reacted propellants. Laser diagnostics of the combustion products near the hot chamber surface and measurements at the surface layer were performed in a collaborative program at Sandia National Laboratories, Livermore, CA. The Material Sample Test Apparatus, a laboratory system to simulate the combustion environment in terms of gas and material temperature, composition, and pressure up to 6 Atm, was developed for these studies. Rocket engine simulator studies were conducted to evaluate the materials under simulated combustor flow conditions, in the diagnostic test chamber. These tests used the exhaust species measurement system, a device developed to monitor optically species composition and concentration in the chamber and exhaust by emission and absorption measurements.
MEMS-based 4H-SiC piezoresistive pressure sensors have been demonstrated at 800 C, leading to the discovery of strain sensitivity recovery with increasing temperatures above 400 C, eventually achieving up to, or near, 100 recovery of the room temperature values at 800 C. This result will allow the insertion of highly sensitive pressure sensors closer to jet, rocket, and hypersonic engine combustion chambers to improve the quantification accuracy of combustor dynamics, performance, and increase safety margin. Also, by operating at higher temperature and locating closer to the combustion chamber, reduction of the length (weight) of pressure tubes that are currently used will be achieved. This will result in reduced costlb to access space.
In recent years, there has been a tendency toward shrinking the size of spacecraft. New classes of spacecraft called micro-spacecraft have been defined by their mass, power, and size ranges. Spacecraft in the range of 20 to 100 kg represent the class most likely to be utilized by most small sat users in the near future. There are also efforts to develop 10 to 20 kg class spacecraft for use in satellite constellations. More ambitious efforts will be to develop spacecraft less than 10 kg, in which MEMS fabrication technology is required. These new micro-spacecraft will require new micro-propulsion technology. Although micro-propulsion includes electric propulsion approaches, the focus of this proposed program is micro-chemical propulsion which requires the development of microcombustors. As combustors are scaled down, the surface to volume ratio increases. The heat release rate in the combustor scales with volume, while heat loss rate scales with surface area. Consequently, heat loss eventually dominates over heat release when the combustor size becomes smaller, thereby leading to flame quenching. The limitations imposed on chamber length and diameter has an immediate impact on the degree of miniaturization of a micro-combustor. Before micro-combustors can be realized, such a difficulty must be overcome. One viable combustion alternative is to take advantage of surface catalysis. Micro-chemical propulsion for small spacecraft can be used for primary thrust, orbit insertion, trajectory-control, and attitude control. Grouping micro-propulsion devices in arrays will allow their use for larger thrust applications. By using an array composed of hundreds or thousands of micro-thruster units, a particular configuration can be arranged to be best suited for a specific application. Moreover, different thruster sizes would provide for a range of thrust levels (from N s to mN s) within the same array. Several thrusters could be fired simultaneously for thrust levels higher than the basic units, or in a rapid sequence in order to provide gradual but steady low-g acceleration. These arrays of micro-propulsion systems would offer unprecedented flexibility and redundancy for satellite propulsion and reaction control for launch vehicles. A high-pressure bi-propellant micro-rocket engine is already being developed using MEMS technology. High pressure turbopumps and valves are to be incorporated onto the rocket chip . High pressure combustion of methane and O2 in a micro-combustor has been demonstrated without catalysis, but ignition was established with a spark. This combustor has rectangular dimensions of 1.5 mm by 8 mm (hydraulic diameter 3.9 mm) and a length of 4.5 mm and was operated at 1250 kPa with plans to operate it at 12.7 MPa. These high operating pressures enable the combustion process in these devices, but these pressures are not practical for pressure fed satellite propulsion systems. Note that the use of these propellants requires an ignition system and that the use of a spark would impose a size limitation to this micro-propulsion device because the spark unit cannot be shrunk proportionately with the thruster. Results presented in this paper consist of an experimental evaluation of the minimum catalyst temperature for initiating/supporting combustion in sub-millimeter diameter tubes. The tubes are resistively heated and reactive premixed gases are passed through the tubes. Tube temperature and inlet pressure are monitored for an indication of exothermic reactions and composition changes in the gases.
An analytical model is formulated for a three-dimensional nonlinear stability problem in a rocket motor combustion chamber. The chamber is modeled as a right circular cylinder with a short (multi-orifice) nozzle, and an acoustic linear covering an arbitrary portion of the cylindrical periphery. The combustion is concentrated at the injector and the gas flow field is characterized by a mean Mach number. The unsteady combustion processes are formulated using the Crocco time lag model. The resulting equations are solved using a Green's function method combined with numerical evaluation techniques. The influence of acoustic liners on the nonlinear waveforms is predicted. Nonlinear stability limits and regions where triggering is possible are also predicted for both lined and unlined combustors in terms of the combustion parameters.
Computational fluid dynamics (CFD) code developed for use in design analyses of flow instabilities associated with combustion of sprayed liquid propellants in rocket engines. Code also contributes to design of improved commercial sprayed-fuel combustors in furnaces and jet engines. Proves robust, user-friendly software tool with comprehensive analysis capability. Enables characterization of stability or instability of engine in terms of such physically meaningful parameters as initial conditions of spray, spatial distribution of ratio between concentrations of fuel and oxidizer at injector faces, geometry of combustor, and configurations of baffles.
The objectives of the present research are to improve design capabilities for low thrust rocket engines through understanding the detailed mixing and combustion processes in a representative combustor. Of particular interest is a small gaseous hydrogen-oxygen thruster which is considered as a coordinated part of an on-going experimental program at NASA LERC. Detailed computational modeling involves the solution of both the two- and three-dimensional Navier Stokes equations, coupled with chemical reactions and the species diffusion equations. Computations of interest include both steady state and time-accurate flowfields and are obtained by means of LU approximate factorization in time and flux split upwinding differencing in space. The emphasis in the research is focused on using numerical analysis to understand detailed combustor flowfields, including the shear layer dynamics created between fuel film cooling and the core gas in the vicinity on the nearby combustor wall; the integrity and effectiveness of the coolant film; and three-dimensional fuel and oxidizer jet injection/mixing/combustion characteristics in the primary combustor along with their joint impacts on global engine performance.
The material to be presented in these two lectures begins with cycle considerations of the turbojet engine combined with a ramjet engine to provide thrust over the range of Mach 0 to 5. We will then examine in some detail the aerodynamic behavior that occurs in the inlet operating near the peak speed. Following that, we shall view a numerical simulation through a baseline scramjet engine, starting at the entrance to the inlet, proceeding into the combustor and through the nozzle. In the next segment, we examine a combined rocket and ramjet propulsion system. Analysis and test results will be examined with a view toward evaluation of the concept as a practical device. Two other inlets will then be reviewed: a Mach 12 inlet and a Mach 18 configuration. Finally, we close our lectures with a discussion of the Detonation Wave engine, and inspect the physical and chemical behavior obtained from numerical simulation. A few final remarks will be made regarding the application of CFD for hypersonic propulsion components.
A test program was performed to evaluate hydrazine (N2H4) as a fuel for a 445 Newton (100 lbf) thrust bipropellant rocket engine. Results of testing with an identical thruster utilizing monomethylhydrazine (MMH) are included for comparison. Engine performance with hydrazine fuel was essentially identical to that experienced with monomethylhydrazine although higher combustor wall temperatures (approximately 400 F) were obtained with hydrazine. Results are presented which indicate that hydrazine as a fuel is compatible with Marquardt bipropellant rocket engines which use monomethylhydrazine as a baseline fuel.