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NASA NTRSDate not supplied

Characterization of an Optically Accessible RP/GOx Rotating Detonation Engine

The accurate characterization of the dynamic response of liquid jets to transient detonation wave passage is crucial for optimizing and modeling liquid-fueled rotating detonation combustors. To address this need, we have developed an optically accessible rocket RDE (RP-RDE), which utilizes liquid RP-1 and gaseous oxygen as propellants and operates at elevated pressures. The experimental setup features optical access from the oxidizer injection plenum to the combustor exit, allowing for detailed characterization of injection, mixing, and combustion processes and their impact on the detonation wave structure. To design and develop the liquid injection scheme for the RP-RDE test article, we employed a combined experimental and numerical approach that included cold-flow simulations. Our aim was to optimize the liquid injection process and ensure that the resulting fuel-oxidizer mixture is homogeneous and stable. To this end, high-speed optical imaging will be employed to provide qualitative visualization of the liquid and gaseous phases of the propellant as well as the local heat release during detonation wave propagation through the non-premixed medium. This work will provide critical insights into the behavior of the transient detonation waves in more relevant rocket conditions, which is essential for the optimization and modeling of rotating detonation combustors.

Propulsion↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Hybrid propulsion has been investigated as an enhancing technology for a Mars Ascent Vehicle (MAV) concept as part of potential Mars Sample Return (MSR) because of its high specific impulse, restartability, and the ability to operate and survive at extremely low temperatures. A new wax-based hybrid fuel formulation has been developed that could withstand the harsh and variable Mars environment protected solely by a minimal layer of passive insulation. This formulation could provide substantial energy savings for a notional lander and is critical for rover mobility. Preliminary thermal cycle testing has determined that the formulation can survive the expected temperature extremes and lifetime thermal testing is currently underway. A complete preliminary design using this new fuel formulation combined with a low temperature oxidizer such as Mixed Oxides of Nitrogen (MON30) is presented. Several key features associated with a complete hybrid MAV concept are investigated to determine their mission suitability (e.g. Thrust Vector Control and restartable ignition options). Potential challenges along a path towards developing such a system are outlined and future work is suggested as a means of technology maturation. The hybrid design presented here was the lowest Gross Lift Off Mass (GLOM) result of a 2015 Jet Propulsion Laboratory (JPL) led MAV concept study.

MSR↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Karp, Ashley C.↗

NASA NTRSDate not supplied

Proof of Concept Testing for Integrated Reaction Control System

Integrated Reaction Control Systems (IRCS) are considered an enabling technology for future human exploration of the solar system. An IRCS uses the same fuel and oxidizer as the main propulsion system, allowing for increased performance and simplified cryogenic fluid management operations. The IRCS team at Marshall Spaceflight Center is currently evaluating an IRCS system that uses a combination of electric pumps and pressure-regulation devices to provide a constant flow of conditioned propellant to a thruster bank during operation. In the spring 2021 test series presented here, the feasibility of this concept was evaluated using liquid nitrogen as a simulant for liquid oxygen. The goal of this test series was to demonstrate the ability of the pump and pressure regulator to maintain adequate thruster inlet conditions during transient operation.

Cameron Hines↗

NASA NTRS2003

Quenching Combustible Dust Mixtures Using Electric Particulate Suspensions (EPS): A New Testing Method For Microgravity

The Electric Particulate Suspension (EPS) is a combustion ignition system being developed at Iowa State University for evaluating quenching effects of powders in microgravity (quenching distance, ignition energy, flammability limits). Because of the high cloud uniformity possible and its simplicity, the EPS method has potential for "benchmark" design of quenching flames that would provide NASA and the scientific community with a new fire standard. Microgravity is expected to increase suspension uniformity even further and extend combustion testing to higher concentrations (rich fuel limit) than is possible at normal gravity. Two new combustion parameters are being investigated with this new method: (1) the particle velocity distribution and (2) particle-oxidant slip velocity. Both walls and (inert) particles can be tested as quenching media. The EPS method supports combustion modeling by providing accurate measurement of flame-quenching distance as a parameter in laminar flame theory as it closely relates to characteristic flame thickness and flame structure. Because of its design simplicity, EPS is suitable for testing on the International Space Station (ISS). Laser scans showing stratification effects at 1-g have been studied for different materials, aluminum, glass, and copper. PTV/PIV and a leak hole sampling rig give particle velocity distribution with particle slip velocity evaluated using LDA. Sample quenching and ignition energy curves are given for aluminum powder. Testing is planned for the KC-135 and NASA s two second drop tower. Only 1-g ground-based data have been reported to date.

Colver, Gerald M.↗

NASA NTRS2013

Component Testing of the J-2X Augmented Spark Igniter (ASI)

In support of the development of the J-2X engine, 201 low pressure, liquid oxygen / liquid hydrogen (LOX/LH2) J-2X Augmented Spark Igniter (ASI) subsystem ignition tests were conducted at Marshall Space Flight Center (MSFC). The main objective of these tests was to start the ASI within the anticipated J-2X engine start box, as well as outside of it, to check for ignition margin. The setup for the J-2X ASI component testing simulated, as much as possible, the tank-head start-up configuration of the ASI within the J-2X Engine. The ignition tests were divided into 124 vacuum start tests to simulate altitude start on a flight engine, and 77 sea-level start tests to simulate the first set of ground tests for the J-2X Engine at Stennis Space Center (SSC). Other ignition parameters that were varied included propellant tank pressures, oxidizer temperature entering the ASI oxidizer feedline, oxidizer valve timing, spark igniter condition (new versus damaged), and oxidizer and fuel feedline orifice sizes. Propellant blowdowns using venturis sized to simulate the ASI resistance allowed calculation of transient propellant mass flow rates as well as global mixture ratio for all ignition tests. Global mixture ratio within the ASI at the time of ignition varied from 0.2 to 1.2. Detailed electronics data obtained from an instrumented ignition lead allowed characterization of the breakdown voltage, sustaining voltage and energy contained in each spark as the ASI propellants ignited. Results indicated that ignition always occurred within the first five sparks when both propellants were present in the ASI chamber.

Osborne, Robin J.↗

NASA NTRS1995

CFD assessment of the pollutant environment from RD-170 propulsion system testing

Computational Fluid Dynamics (CFD) technology has been used to assess the exhaust plume pollutant environment of the RD-170 engine hot-firing on the F1 Test Stand at Marshall Space Flight Center. Researchers know that rocket engine hot-firing has the potential for forming thermal nitric oxides (NO(x)), as well as producing carbon monoxide (CO) when hydrocarbon fuels are used. Because of the complicated physics involved, however, little attempt has been made to predict the pollutant emissions from ground-based engine testing, except for simplified methods which can grossly underpredict and/or overpredict the pollutant formations in a test environment. The objective of this work, therefore, has been to develop a technology using CFD to describe the underlying pollutant emission physics from ground-based rocket engine testing. This resultant technology is based on a three-dimensional (3D), viscous flow, pressure-based CFD formulation, where wet CO and thermal NO finite-rate chemistry mechanisms are solved with a Penalty Function method. A nominal hot-firing of a RD-170 engine on the F1 stand has been computed. Pertinent test stand flow physics such as the multiple-nozzle clustered engine plume interaction, air aspiration from base and aspirator, plume mixing with entrained air that resulted in contaminant dilution and afterburning, counter-afterburning due to flame bucket water-quenching, plume impingement on the flame bucket, and restricted multiple-plume expansion and turning have been captured. The predicted total emission rates compared reasonably well with those of the existing hydrocarbon engine hot-firing test data.

Wang, Ten-See↗

NASA NTRS1972

Pollution measurements of a swirl-can combustor.

Pollutant levels of oxides of nitrogen, unburned hydrocarbons, and carbon monoxide were measured for an experimental, annular, swirl-can combustor. The combustor was 42 inches in diameter, incorporated 120 modules, and was specifically designed for elevated exit temperature performance. Test conditions included combustor inlet temperatures of 600, 900 and 1050 F, inlet pressures of 5 to 6 atmospheres, reference velocities of 69 to 120 feet per second, and fuel-air ratios of 0.014 to 0.0695. Tests were also conducted at a simulated engine idle condition. Results demonstrated that swirl-can combustors produce oxides of nitrogen levels substantially lower than conventional combustor designs.

Niedzwiecki, R. W.↗

NASA NTRS2007

Ceramic Integration Technologies for Aerospace and Energy Systems: Technical Challenges and Opportunities

Ceramic integration technology has been recognized as an enabling technology for the implementation of advanced ceramic systems in a number of high-temperature applications in aerospace, power generation, nuclear, chemical, and electronic industries. Various ceramic integration technologies (joining, brazing, attachments, repair, etc.) play a role in fabrication and manufacturing of large and complex shaped parts of various functionalities. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Experimental results for bonding and integration of SiC based LDI fuel injector, high conductivity C/C composite based heat rejection system, solid oxide fuel cells system, ultra high temperature ceramics for leading edges, and ceramic composites for thermostructural applications will be presented. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be discussed.

Singh, Mrityunjay↗

NASA NTRS1978

Effect of inlet temperature on the performance of a catalytic reactor

A 12 cm diameter by 15 cm long catalytic reactor was tested with No. 2 diesel fuel in a combustion test rig at inlet temperatures of 700, 800, 900, and 1000 K. Other test conditions included pressures of 3 and 6 x 10 to the 5th power Pa, reference velocities of 10, 15, and 20 m/s, and adiabatic combustion temperatures in the range 1100 to 1400 K. The combustion efficiency was calculated from measurements of carbon monoxide and unburned hydrocarbon emissions. Nitrogen oxide emissions and reactor pressure drop were also measured. At a reference velocity of 10 m/s, the CO and unburned hydrocarbons emissions, and, therefore, the combustion efficiency, were independent of inlet temperature. At an inlet temperature of 1000 K, they were independent of reference velocity. Nitrogen oxides emissions resulted from conversion of the small amount (135 ppm) of fuel-bound nitrogen in the fuel. Up to 90 percent conversion was observed with no apparent effect of any of the test variables. For typical gas turbine operating conditions, all three pollutants were below levels which would permit the most stringent proposed automotive emissions standards to be met.

Anderson, D. N.↗

NASA NTRS1976

Nonintrusive Flowmeter

The results of analytical and experimental work performed in the design, fabrication, and test of a prototype nonintrusive gaging system for use in monitoring the consumption of earth-storable fuels and oxidants in either a one-g or a zero-g environment are explained. The design specifications were those applicable to the reaction control system and to the orbital maneuvering system (OMS) fuel and oxidant on the space shuttle while in orbit. The major requirement was for the measurement of flow pulses with sufficient accuracy to provide a continuous knowledge of the fuel and oxidant remaining in the OMS system to within 1% or better. An ultrasonic frequency chirp technique was used having a high inherent rejection for signals traversing stray paths, and for random noise generated by the flowing liquid. A detailed analysis of the frequency chirp approach for two modes of operation (period and phase changes), including an error analysis are reported.

Greene, M. W.↗

NASA NTRSDate not supplied

Mixing and Recovery Performance of Triplet Impinging Injectors with Varying Flow Areas for Detonative Combustion

Detonation combustion devices such as rotating detonation rocket engines (RDREs) have been proposed as an alternative to traditional deflagration engines as detonative combustion has a higher theoretical thermodynamic efficiency. Improved performance of an RDRE depends heavily on the propellant injection and mixing. Impingement type injectors have been shown to achieve higher characteristic velocity or combustion efficiency for both detonative and deflagrative engines. This work is exploratory in nature and focuses on unlike triplet impinging injectors to study how the flow area of the injector affects the mixing of propellants and recovery under the transient, high-peak pressure conditions unique to RDREs. A ratio of fuel flow area to oxidizer flow area is set to achieve a given mass flow rate and thus propellant mixture ratio. Four different fluid flow areas are studies while keeping the fuel/oxidizer ratio constant. This work has found that, while maintaining a fixed ratio fuel to oxidizer flow area, the injectors with smaller orifice areas show better resistance to backflow in steady state tests and have shorter recovery times in backflow experiments. Even with the shorter recovery times, it is found that the shortest recovery time is still an order of magnitude slower than the frequency of a single detonation wave traversing a 3” RDRE.

Michaela R. Hemming↗

NASA NTRS1973

Sampling nitric oxide from combustion gases.

Experimental study of several sampling tube and probe material compositions and designs aimed at preventing nitric oxide reduction when sampling nitric oxide from combustion gases. A 250,000 Btu/h furnace fired with technical grade methane was used for testing the sampling probes over a wide range of air-fuel mixtures. The results obtained include the finding that the use of stainless steel in probes creates inaccuracies in near-stoichiometric and fuel-rich sampling in hydrocarbon flames. For very fuel-rich flames, water cooling is needed even in quartz probes to prevent significant reduction of nitric oxide.-

England, C.↗

NASA NTRS2018

Orion European Structural Test Article Propellant Tank Fill and Drain Carts

Environmental testing of the Orion European Structural Test Article (E-STA), which contains the Orion European Service Module (ESM), required that the onboard propellant tanks be filled and drained with fuel and oxidizer simulant fluids as well as pressurized and depressurized with an ullage gas. This conference paper will elaborate on how these objectives were fulfilled by presenting the development of derived requirements definition, initial fill and drain concepts, selection of simulant fluids, finalization of pump and pressurization design, selection of components, and selection of transfer hoses and interface connections as well as development and maintenance of budgets, schedules, reviews, construction, documentation, and test procedures. This paper also describes the implementation of checkout and commissioning activities leading to successful fluid cart pumping and pressurization operations for the test campaign. The development, construction, and operation of the fluid cart pumping and pressurization systems for the environmental testing of the Orion E-STA, took place at NASA's Plum Brook Station Space Environments Complex (SEC) during 2015 and 2016.

FLUID TRANSFER↗

NASA NTRS2018

Orion European Structural Test Article Propellant Tank Fill and Drain Carts

Environmental testing of the Orion European Structural Test Article (E-STA), which contains the Orion European Service Module (ESM), required that the onboard propellant tanks be filled and drained with fuel and oxidizer simulant fluids as well as pressurized and de-pressurized with an ullage gas. This conference paper will elaborate on how these objectives were fulfilled by presenting the development of derived requirements definition, initial fill and drain concepts, selection of simulant fluids, finalization of pump and pressurization design, selection of components, selection of transfer hoses and interface connections, as well as development and maintenance of budgets, schedules, reviews, construction, documentation, and test procedures. This paper also describes implementation of checkout and commissioning activities leading to successful fluid cart pumping and pressurization operations for the test campaign. The development, construction, and operation of the fluid cart pumping and pressurization systems for the Environmental testing of the Orion European Structural Test Article (E-STA), took place at the NASA Glenn Research Center's Plum Brook Station Space Environments Complex (SEC) during 2015 and 2016.

Pressurization↗

NASA NTRS1997

Space Shuttle Main Engine Start with Off-Nominal Propellant Inlet Pressures

This paper describes Rocketdyne's successful analysis and demonstration of the Space Shuttle Main Engine (SSME) operation at off-nominal propellant inlet conditions during the Reusable Launch Vehicle (RLV) evaluation tests. The nominal inlet condition range is: 103 to 111 psia and 170.5 to 178 deg. R for the oxidizer and 43 to 47 psia and 37 to 40 deg. R for the fuel. The SSME start was successfully demonstrated with engine inlet pressures of 50 psia liquid oxygen (LOX) with subcooled LOX at 160 deg R and 38 psia fuel at 38 deg. R. Four tests were used to incrementally modify the start sequence to demonstrate the final goal.

Bradley, Michael↗

NASA NTRS2004

New Screening Test Developed for the Blanching Resistance of Copper Alloys

NASA's extensive efforts towards more efficient, safer, and more affordable space transportation include the development of new thrust-cell liner materials with improved capabilities and longer lives. For rocket engines fueled with liquid hydrogen, an important metric of liner performance is resistance to blanching, a phenomenon of localized wastage by cycles of oxidation-reduction due to local imbalance in the oxygen-fuel ratio. The current liner of the Space Shuttle Main Engine combustion chamber, a Cu-3Ag-0.5Zr alloy (NARloy-Z) is degraded in service by blanching. Heretofore, evaluating a liner material for blanching resistance involved elaborate and expensive hot-fire tests performed on rocket test stands. To simplify that evaluation, researchers at the NASA Glenn Research Center developed a screening test that uses simple, in situ oxidation-reduction cycling in a thermogravimetric analyzer (TGA). The principle behind this test is that resistance to oxidation or to the reduction of oxide, or both, implies resistance to blanching. Using this test as a preliminary tool to screen alloys for blanching resistance can improve reliability and save time and money. In this test a small polished coupon is hung in a TGA furnace at the desired (service) temperature. Oxidizing and reducing gases are introduced cyclically, in programmed amounts. Cycle durations are chosen by calibration, such that all copper oxides formed by oxidation are fully reduced in the next reduction interval. The sample weight is continuously acquired by the TGA as usual.

Thomas-Ogbuji, Linus U.↗

NASA NTRS2023

High-Pressure, Normal-Gravity Droplet Combustion Experimental Hardware

The High-Pressure, Trans-Critical (HPTC) 1-g Liquid Droplet Combustion Experiments will assess the autoignition and combustion of liquid fuel droplets at elevated temperatures and pressures. These experiments are being conducted at the NASA Glenn Research Center in a manner similar to experiments performed in Glenn’s Zero Gravity Research Facility (ZGF) using the B drop vehicle. The modification to the test capabilities of the ZGF experiments in the new experimental configuration will allow researchers to continue performing normal-gravity liquid droplet combustion experiments without requiring the use of the ZGF test equipment. These normal-gravity experiments will be conducted at lower pressures than in the ZGF because the pressure vessel for this setup is limited to a maximum working pressure of 7.74 atm (99.1 psig) at 366.5 K (200 °F). This experimental configuration will enable development of a similar capability for conducting high-pressure combustion and supercritical oxidation research on the International Space Station. Experiments will be conducted with the capability of altering the ambient pressure, temperature, and gas concentrations, as well as the fuel type for each test. For these experiments, the test vessel operates at pressures up to 7.5 atm (95.5 psig), temperatures up to 1,073 K (1,472 °F) inside the insulated oven, and oxygen concentrations up to 30 percent.

Droplet Combustion↗