Additive Manufacturing Developments for Rocket Engines: Applications, Advanced Materials and Large Scale Techniques
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Advanced carbon-carbon nozzle materials can reduce the weight and improve the efficiency of the proposed reusable Orbit Transfer Vehicle (OTV) liquid rocket engine. Experimental evaluations of eight carbon-carbon materials in an O2/H2 rocket nozzle environment have been performed. The hot fire testing will support the choice of the materials for the OTV nozzle design. The OTV nozzle requirements and operating environment are defined. The rocket device used to simulate the OTV hot-fire nozzle environment for material specimen evaluation is described. The results of hot-fire testing for eight carbon-carbon materials are discussed. Results for coated and uncoated materials, evaluated in side-by-side testing, are compared. Plans for further testing of the leading materials are described.
Quantitative design criteria for priori injector designs yielding combustion process compatible with thrust chamber-nozzle materials
An evaluation is presented of J-2 engine modifications that will simplify operation and improve reliability of the advanced Saturn 1C launch vehicle. Methods of increasing thrust without extensively modifying the S-2 or S-4B stages are also evaluated. A thrust increase was achieved by raising engine combustion through a redesign of the engine thrust chamber and propellant feed system.
This paper will describe the thermal analysis techniques used to predict temperatures in the film-cooled ablative rocket nozzle used on the Fastrac 60K rocket engine. A model was developed that predicts char and pyrolysis depths, liner thermal gradients, and temperatures of the bondline between the overwrap and liner. Correlation of the model was accomplished by thermal analog tests performed at Southern Research, and specially instrumented hot fire tests at the Marshall Space Flight Center. Infrared thermography was instrumental in defining nozzle hot wall surface temperatures. In-depth and outboard thermocouple data was used to correlate the kinetic decomposition routine used to predict char and pyrolysis depths. These depths were anchored with measured char and pyrolysis depths from cross-sectioned hot-fire nozzles. For the X-34 flight analysis, the model includes the ablative Thermal Protection System (TPS) material that protects the overwrap from the recirculating plume. Results from model correlation, hot-fire testing, and flight predictions will be discussed.
The purpose of the program is to perform design studies and analyses to determine the effects of incorporating a 60:1 expansion area ratio nozzle extension, extended firing time, and modified operating conditions and environments on the MM'71 rocket engine assembly. An injector-to-thrust chamber seal study was conducted to define potential solutions for leakage past this joint. The results and recommendations evolving from the engine thermal analyses, the injector-to-thrust chamber seal studies, and the nozzle extension joint stress analyses are presented.
Flight subliming solid respin rocket system development for OV2-1 satellite and nozzle optimization performance studies
No abstract available
The objectives of the research are to improve design capabilities for low thrust rocket engines through understanding of the detailed mixing and combustion processes. A Computational Fluid Dynamic (CFD) technique is employed to model the flowfields within the combustor, nozzle, and near plume field. The computational modeling of the rocket engine flowfields requires the application of the complete Navier-Stokes equations, coupled with species diffusion equations. Of particular interest is a small gaseous hydrogen-oxygen thruster which is considered as a coordinated part of an ongoing experimental program at NASA LeRC. The numerical procedure is performed on both time-marching and time-accurate algorithms, using an LU approximate factorization in time, flux split upwinding differencing in space. The integrity of fuel film cooling along the wall, its effectiveness in the mixing with the core flow including unsteady large scale effects, the resultant impact on performance and the assessment of the near plume flow expansion to finite pressure altitude chamber are addressed.
A new rocket engine concept that is presently being evaluated offers significant performance, cost, and configurational advantages. The Linear Rocket Engine System, (LRES) combines the unique performance and operational advantages of the aerospike nozzle with the configuration versatility of low cost modular combustors, which results in a high-performance rocket engine package designed specifically for use in advanced configuration vehicles. This paper describes the design, fabrication, and testing of the LRES concept to evaluate its potential for vehicle integration. The program was conducted under the sponsorship of NASA's Marshall Space Flight Center.
Thrust vector control for solid propellant rocket engines - liquid injection system, hot or cold gas systems, and gimballed nozzle systems
Pyrolytic graphite rocket thrust chamber
Colloidal particle generator for electrostatic rocket engine using a convergent-divergent nozzle
Hot-gas side heat-transfer rates for liquid oxygen and hydrogen propellant rocket nozzle
Scale model compressed air tests of 260-inch solid rocket with submerged nozzle to determine exhaust flow velocity and direction in annular channel
Ablation cooling in rocket engine with combustion chamber liner and nozzle constructed of silica phenolic ablative material
Hafnia-based composites containing either graphite or tungsten were investigated as rocket nozzle throat inserts in solid propellant rocket engines. The thermal shock resistance of these materials is considered in terms of macroscopic thermal conductivity, thermal expansion, modulus of elasticity, and compressive fracture stress. The effect of degree of hafnia stabilization, density, and graphite or tungsten content upon these parameters is discussed. The variation of the ratio of elastic modulus to compressive fracture stress with density and its effect upon thermal shock resistance of these materials are discussed in detail.
As described in Vol. 1, the eddy viscosity is calculated through the turbulent kinetic energy, in order to include the history of the flow and the effect of chemical reaction on boundary layer characteristics. Calculations can be performed for two different cooling concepts; that is, transpiration and regeneratively cooled wall cases. For the regenerative cooling option, coolant and gas side wall temperature and coolant bulk temperature in a rocket engine can be computed along the nozzle axis. Thus, this computer program is useful in designing coolant flow rate and cooling tube geometry, including the tube wall thickness as well as in predicting the effects of boundary layers along the gas side wall on thrust performances.