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NASA NTRS2010

Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles

The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests and/or deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four degrees of ovalization of the nozzle: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The computed side load physics caused by the nozzle out-of-roundness and its effect on nozzle side load are reported and discussed.

Wang, Ten-See↗

NASA NTRS2010

Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles

The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads at a high altitude, with an anchored computational methodology. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests, and deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four different degrees of ovalization: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation-line-jump is the peak side load physics for the round, slightly our-of-round, and more out-of-round cases, and the peak side load increases as the degree of out-of-roundness increases. For the significantly out-of-round nozzle, however, the peak side load reduces to comparable to that of the round nozzle and the separation line jump is not the peak side load physics. The counter-intuitive result of the significantly out-of-round case is found to be related to a side force reduction mechanism that splits the effect of the separation-line-jump into two parts, not only in the circumferential direction and most importantly in time.

Wang, Ten-See↗

NASA NTRS2012

Transient Side Load Analysis of Out-of-Round Film-Cooled Nozzle Extensions

There was interest in understanding the impact of out-of-round nozzle extension on the nozzle side load during transient startup operations. The out-of-round nozzle extension could be the result of asymmetric internal stresses, deformation induced by previous tests, and asymmetric loads induced by hardware attached to the nozzle. The objective of this study was therefore to computationally investigate the effect of out-of-round nozzle extension on the nozzle side loads during an engine startup transient. The rocket engine studied encompasses a regeneratively cooled chamber and nozzle, along with a film cooled nozzle extension. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and transient inlet boundary flow properties derived from an engine system simulation. Six three-dimensional cases were performed with the out-of-roundness achieved by three different degrees of ovalization, elongated on lateral y and z axes: one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation line jump was the primary source of the peak side loads. Comparing to the peak side load of the perfectly round nozzle, the peak side loads increased for the slightly and more ovalized nozzle extensions, and either increased or decreased for the two significantly ovalized nozzle extensions. A theory based on the counteraction of the flow destabilizing effect of an exacerbated asymmetrical flow caused by a lower degree of ovalization, and the flow stabilizing effect of a more symmetrical flow, created also by ovalization, is presented to explain the observations obtained in this effort.

Wang, Ten-See↗

NASA NTRS2013

Thermal Hydraulics Design and Analysis Methodology for a Solid-Core Nuclear Thermal Rocket Engine Thrust Chamber

Nuclear thermal propulsion is a leading candidate for in-space propulsion for human Mars missions. This chapter describes a thermal hydraulics design and analysis methodology developed at the NASA Marshall Space Flight Center, in support of the nuclear thermal propulsion development effort. The objective of this campaign is to bridge the design methods in the Rover/NERVA era, with a modern computational fluid dynamics and heat transfer methodology, to predict thermal, fluid, and hydrogen environments of a hypothetical solid-core, nuclear thermal engine the Small Engine, designed in the 1960s. The computational methodology is based on an unstructured-grid, pressure-based, all speeds, chemically reacting, computational fluid dynamics and heat transfer platform, while formulations of flow and heat transfer through porous and solid media were implemented to describe those of hydrogen flow channels inside the solid24 core. Design analyses of a single flow element and the entire solid-core thrust chamber of the Small Engine were performed and the results are presented herein

Wang, Ten-See↗

NASA NTRS2013

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development during test. While three-dimensional, transient, turbulent, chemically reacting computational fluid dynamics methodology has been demonstrated to capture major side load physics with rigid nozzles, hot-fire tests often show nozzle structure deformation during major side load events, leading to structural damages if structural strengthening measures were not taken. The modeling picture is incomplete without the capability to address the two-way responses between the structure and fluid. The objective of this study is to develop a coupled aeroelastic modeling capability by implementing the necessary structural dynamics component into an anchored computational fluid dynamics methodology. The computational fluid dynamics component is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, while the computational structural dynamics component is developed in the framework of modal analysis. Transient aeroelastic nozzle startup analyses of the Block I Space Shuttle Main Engine at sea level were performed. The computed results from the aeroelastic nozzle modeling are presented.

Wang, Ten-See↗

NASA NTRS2013

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Wang, Ten-See↗

NASA NTRS2014

Aeroelastic Modeling of a Nozzle Startup Transient

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development during test. While three-dimensional, transient, turbulent, chemically reacting computational fluid dynamics methodology has been demonstrated to capture major side load physics with rigid nozzles, hot-fire tests often show nozzle structure deformation during major side load events, leading to structural damages if structural strengthening measures were not taken. The modeling picture is incomplete without the capability to address the two-way responses between the structure and fluid. The objective of this study is to develop a tightly coupled aeroelastic modeling algorithm by implementing the necessary structural dynamics component into an anchored computational fluid dynamics methodology. The computational fluid dynamics component is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, while the computational structural dynamics component is developed under the framework of modal analysis. Transient aeroelastic nozzle startup analyses at sea level were performed, and the computed transient nozzle fluid-structure interaction physics presented,

Wang, Ten-See↗

NASA NTRS2010

A GPS-Based Pitot-Static Calibration Method Using Global Output-Error Optimization

Pressure-based airspeed and altitude measurements for aircraft typically require calibration of the installed system to account for pressure sensing errors such as those due to local flow field effects. In some cases, calibration is used to meet requirements such as those specified in Federal Aviation Regulation Part 25. Several methods are used for in-flight pitot-static calibration including tower fly-by, pacer aircraft, and trailing cone methods. In the 1990 s, the introduction of satellite-based positioning systems to the civilian market enabled new inflight calibration methods based on accurate ground speed measurements provided by Global Positioning Systems (GPS). Use of GPS for airspeed calibration has many advantages such as accuracy, ease of portability (e.g. hand-held) and the flexibility of operating in airspace without the limitations of test range boundaries or ground telemetry support. The current research was motivated by the need for a rapid and statistically accurate method for in-flight calibration of pitot-static systems for remotely piloted, dynamically-scaled research aircraft. Current calibration methods were deemed not practical for this application because of confined test range size and limited flight time available for each sortie. A method was developed that uses high data rate measurements of static and total pressure, and GPSbased ground speed measurements to compute the pressure errors over a range of airspeed. The novel application of this approach is the use of system identification methods that rapidly compute optimal pressure error models with defined confidence intervals in nearreal time. This method has been demonstrated in flight tests and has shown 2- bounds of approximately 0.2 kts with an order of magnitude reduction in test time over other methods. As part of this experiment, a unique database of wind measurements was acquired concurrently with the flight experiments, for the purpose of experimental validation of the optimization method. This paper describes the GPS-based pitot-static calibration method developed for the AirSTAR research test-bed operated as part of the Integrated Resilient Aircraft Controls (IRAC) project in the NASA Aviation Safety Program (AvSP). A description of the method will be provided and results from recent flight tests will be shown to illustrate the performance and advantages of this approach. Discussion of maneuver requirements and data reduction will be included as well as potential applications.

Foster, John V.↗

NASA NTRS1983

An evaluation of Space Shuttle Orbiter forward fuselage surface pressures - Comparison with wind tunnel and theoretical predictions

In order for ground-based pressure distribution techniques to be verified by the actual performance of the Space Shuttle Orbiter in flight, a comparative study of flight pressure data and both wind tunnel and computational data is presented. The flight pressure data, obtained from measurements on the Orbiter's surface during atmospheric reentry, are part of the overall Orbiter flight data system designated Development Flight Instrumentation. Also given is an analysis of the Orbiter pressure data system, including its transducers, their behavior, and their calibration. The two analyses are the bases of an error assessment calculation for the flight data, as well as an explanation of any discrepancies between flight and ground-based data.

Bradley, P. F.↗

NASA NTRS1992

Adaptation of multidimensional group particle tracking and particle wall-boundary condition model to the FDNS code

A particulate two-phase flow CFD model was developed based on the FDNS code which is a pressure based predictor plus multi-corrector Navier-Stokes flow solver. Turbulence models with compressibility correction and the wall function models were employed as submodels. A finite-rate chemistry model was used for reacting flow simulation. For particulate two-phase flow simulations, a Eulerian-Lagrangian solution method using an efficient implicit particle trajectory integration scheme was developed in this study. Effects of particle-gas reaction and particle size change to agglomeration or fragmentation were not considered in this investigation. At the onset of the present study, a two-dimensional version of FDNS which had been modified to treat Lagrangian tracking of particles (FDNS-2DEL) had already been written and was operational. The FDNS-2DEL code was too slow for practical use, mainly because it had not been written in a form amenable to vectorization on the Cray, nor was the full three-dimensional form of FDNS utilized. The specific objective of this study was to reorder to calculations into long single arrays for automatic vectorization on the Cray and to implement the full three-dimensional version of FDNS to produce the FDNS-3DEL code. Since the FDNS-2DEL code was slow, a very limited number of test cases had been run with it. This study was also intended to increase the number of cases simulated to verify and improve, as necessary, the particle tracking methodology coded in FDNS.

Chen, Y. S.↗

NASA NTRS1999

Reduction of Base Drag on Launch Vehicles

This report describes the work accomplished during a first-year investigation of base drag reduction for launch vehicles. Interest in this work has arisen due to the large base areas associated with the current generation of launch vehicles. For example, the X-33 and Venture Star configurations all have large base areas because of the aero-spike engines they use. Because of the large base-to-wetted area ratios of these vehicles, the majority of the vehicle drag is due to base drag. Based on previous research, there appears to be a means for reducing the base drag on such vehicles. A clear relationship between viscous fore-body drag and base drag was demonstrated. For subsonic flow conditions, an increase in fore-body drag causes a decrease in base drag. This base-drag reduction is a result of boundary layer effects at the base of the vehicle. The shear layer that develops from the boundary layer separating at the back of the vehicle is the conduit through which momentum is transferred from the high energy free-stream flow to the low-energy fluid in the base area. One way to think of the base drag is that it is the momentum required to accelerate this low-energy fluid. The boundary layer that develops on the fore body acts as an "insulator" between the external flow and the low-energy air at the base. As the viscous fore-body drag is increased, the boundary layer thickness at the aft end of the fore body increases, thereby reducing the rate at which momentum is transferred to the base area. As a result of the lower momentum transfer (or reduced pumping), the base pressure coefficient rises resulting in a reduction of base drag.

Naughton, Jonathan↗

NASA NTRS2004

Transient Three-Dimensional Analysis of Side Load in Liquid Rocket Engine Nozzles

Three-dimensional numerical investigations on the nozzle start-up side load physics were performed. The objective of this study is to identify the three-dimensional side load physics and to compute the associated aerodynamic side load using an anchored computational methodology. The computational methodology is based on an unstructured-grid, and pressure-based computational fluid dynamics formulation, and a simulated inlet condition based on a system calculation. Finite-rate chemistry was used throughout the study so that combustion effect is always included, and the effect of wall cooling on side load physics is studied. The side load physics captured include the afterburning wave, transition from free- shock to restricted-shock separation, and lip Lambda shock oscillation. With the adiabatic nozzle, free-shock separation reappears after the transition from free-shock separation to restricted-shock separation, and the subsequent flow pattern of the simultaneous free-shock and restricted-shock separations creates a very asymmetric Mach disk flow. With the cooled nozzle, the more symmetric restricted-shock separation persisted throughout the start-up transient after the transition, leading to an overall lower side load than that of the adiabatic nozzle. The tepee structures corresponding to the maximum side load were addressed.

Wang, Ten-See↗

NASA NTRS2016

Design of a Two-Stage Light Gas Gun for Muzzle Velocities of 10 - 11 kms

Space debris poses a major risk to spacecraft. In low earth orbit, impact velocities can be 10 11 kms and as high as 15 kms. For debris shield design, it would be desirable to be able to launch controlled shape projectiles to these velocities. The design of the proposed 10 11 kmsec gun uses, as a starting point, the Ames 1.280.22 two stage gun, which has achieved muzzle velocities of 10 11.3 kmsec. That gun is scaled up to a 0.3125 launch tube diameter. The gun is then optimized with respect to maximum pressures by varying the pump tube length to diameter ratio (LD), the piston mass and the hydrogen pressure. A pump tube LD of 36.4 is selected giving the best overall performance. Piezometric ratios for the optimized guns are found to be 2.3, much more favorable than for more traditional two stage light gas guns, which range from 4 to 6. The maximum powder chamber pressures are 20 to 30 ksi. To reduce maximum pressures, the desirable range of the included angle of the cone of the high pressure coupling is found to be 7.3 to 14.6 degrees. Lowering the break valve rupture pressure is found to lower the maximum projectile base pressure, but to raise the maximum gun pressure. For the optimized gun with a pump tube LD of 36.4, increasing the muzzle velocity by decreasing the projectile mass and increasing the powder loads is studied. It appears that saboted spheres could be launched to 10.25 and possibly as high as 10.7 10.8 kmsec, and that disc-like plastic models could be launched to 11.05 kms. The use of a tantalum liner to greatly reduce bore erosion and increase muzzle velocity is discussed. With a tantalum liner, CFD code calculations predict muzzle velocities as high as 12 to 13 kms.

Gun Design↗

NASA NTRSDate not supplied

Modeling of Particle Transport and Impact in Transient, Multiphase Oxidizer-Rich Environments Using Computational Fluid Dynamics and Lagrangian Particle Tracking

Particle impacts from foreign object debris (FOD) in an oxidizer-rich environment have been shown to be a credible and significant risk for ignition and failure of components and vehicles. The risk of particle ignition is dependent on many factors, including particle impact velocity/energy and fluid composition (i.e. fluid phase, species presence, and state). Prediction of particle transport and particle impacts in relevant environments, including transient, multiphase flows, is important for assessing the risk and avoiding repeated expensive system level tests. The capability to model both the fluid dynamics and particle transport in complex three-dimensional geometries and multiphase environments has been developed at Marshall Space Flight Center (MSFC) in the propulsion fluid dynamic branch (ER42) by utilizing computational fluid dynamics (CFD) simulations and Lagrangian particle tracking. Using CFD tools, including density-based Loci/CHEM with a cavitation model and pressure-based Loci/STREAM with a volume of fluids model, MSFC/ER42 has provided particle impact predictions to multiple projects for oxidizer compatibility assessments. Simulations of transient, multiphase environments such as liquid slugs flowing through tubing and cavitating flow in valves have been completed alongside one-way coupled Lagrangian particle tracking to predict particle impacts.

M.V. Fischels↗

NASA NTRS1985

Measurement of the Density of Base Fluids at Pressures 0.422 to 2.20 Gpa

The influence of pressure on the density of six base fluids is experimentally studied for a range of pressures from 0.422 to 2.20 GPa. An important parameter used to describe the results is the change in relative volume with change in pressure dv sub r/dp. For pressures less than the solidification pressure (p ps) a small change in pressure results in a large change in dv sub r/ps. For pressures greater than the solidification pressure (p ps) there is no change in dv sub r/dp with changing pressure. The solidification pressures of the base fluids varies considerably, as do the slopes that the experimental data assumes for p ps. A new formula is developed that describes the effect of pressure on density in terms of four constants. These constants vary for the different base fluids tested.

Hamrock, B. J.↗

NASA NTRS1954

Experimental Investigation of Effects of Primary Jet Flow and Secondary Flow Through a Zero-length Ejector on Base and Boattail Pressures of a Body of Revolution at Free-stream Mach Numbers of 1.62, 1.93, and 2.41

An investigation was made at free-stream Mach numbers of 1.62, 1.93, and 2.41 to determine the effects of a primary jet and secondary air flow on the base pressure and pressures acting over the boattailsurface of a body of revolution for two secondary discharge areas. The Mach numbers of the primary nozzles were 1 and 3.23 with the secondary mass flow being varied from 0 to 10 percent of the primary mass flow. The ratio of jet stagnation temperature to tunnel stagnation temperature was about 0.96. The Reynolds number range of the investigation was from 2.1 x 10(6) to 2.9 x 10(6)based on body length. All testing was conducted with a turbulent boundary layer along the model. This report presents results obtained with zero-length ejector and covers jet static-pressure ratios from the jet-off condition to a maximum of about 128 for the sonic nozzle and to a maximum of about 9 for the supersonic nozzle.

O'Donnell, Robert M↗

NASA NTRS1987

Simulation of real-gas effects on pressure distributions for a proposed Aeroassist Flight Experiment vehicle and comparison to prediction

Pressure distributions measured on a 60-deg elliptic cone, raked off at a 73-deg angle and having an ellipsoid nose (ellipticity equal to 2.0), are presented for a range of angle of attack from -10 to 15 deg. The high normal shock density ratio aspect of a real gas was simulated by testing in Mach-6 air (normal shock density ratio equal to 5.25) and Mach 6 CF4 (normal shock density ratio equal to 12.0). The effects of Reynolds number, angle of attack, and normal shock density ratio on these measurements are examined, and comparisons are made to an inviscid flowfield computer code known as HALIS. A significant effect of density ratio on pressure distributions on the cone section of the configuration was observed; the magnitude of this effect decreased with increased angle of attack. The effect of Reynolds number on pressures was negligible for forebody pressure distributions, but a measurable effect was noted on base pressures. In general, the HALIS code accurately predicted the measured pressure distributions in air and CF4.

Micol, John R.↗

NASA NTRS1992

Simulation of real-gas effects on pressure distributions for aeroassist flight experiment vehicle and comparison with prediction

Pressure distributions measured on a 60 degree half-angle elliptic cone, raked off at an angle of 73 degrees from the cone centerline and having an ellipsoid nose (ellipticity equal to 2.0 in the symmetry plane) are presented for angles of attack from -10 degrees to 10 degrees. The high normal shock density ratio aspect of a real gas was simulated by testing in Mach 6 air and CF sub 4 (density ratio equal to 5.25 and 12.0, respectively). The effects of Reynolds number, angle of attack, and normal shock density ratio on these measurements are examined, and comparisons with a three dimensional Euler code known as HALIS are made. A significant effect of density ratio on pressure distributions on the cone section of the configuration was observed; the magnitude of this effect decreased with increasing angle of attack. The effect of Reynolds number on pressure distributions was negligible for forebody pressure distributions, but a measurable effect was noted on base pressures. In general, the HALIS code accurately predicted the measured pressure distributions in air and CF sub 4.

Micol, John R.↗