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NASA NTRS2022

Design of Hypervelocity Flow Generator (HFG) and Its Diagnostics

Ground facilities for hypersonic research are a key element for successful development of aerodynamically proven hypervelocity vehicles. Design concepts and diagnostics of a hypervelocity flow generator (HFG) were made as a test platform for hypersonic/hypervelocity spacecraft models at the NASA Langley Research Center. The HFG is a hypersonic flow field generator using optically heated gas which is blown into an 80 cu m vacuum chamber. The vacuum chamber is kept at a stable vacuum pressure with a combination of three large vacuum pumps, while the HFG is in the test mode. The HFG provides a relatively small test section with approximately a 20 cm window. This facility was designed to generate 2.45 km/sec of flow speed, and potentially generate a continuous flow with the nozzle and vacuum system. The window in test section provides a direct view of the shock wave around a model in order to measure temperature, pressure, and density profile within the shock layer. One of the key test goals under this project is to understand why the emission spectra from the standing shockwave plasma predicted by Lora-Loran codes are significantly different from the measured emission spectra from the Flight Investigation Reentry Environment (FIRE II) Flight. The correct estimate of the thermal loading on the leading edge of hypersonic vehicles greatly affects the aerodynamic design, the material selection for the vehicle, and the cooling requirement and can be obtained by the precise modeling of emission spectra from shockwave plasma. However, the estimation of thermal loading is not an easy task due to complex non-equilibrium radiative process within high temperature shock layers that still falls into a category of cold plasma. Direct flight experiments are the most desirable, but not a cost-effective approach. Analysis by computational fluid dynamics (CFD) offers many test flexibilities. However, the CFD codes must be fully tested and validated with experimental data before the codes are effectively used for practical design. Large discrepancies between experiments and codes appear in hypersonic/hypervelocity flow regimes at high altitudes of 60 km ~ 90 km. This HFG facility offers some important parameters for CFD code validation, such as collision cross-sections, relaxation times, reaction rate coefficients and transportation coefficients. The HFG test facility is based on the ejection flow of high temperature gas heated over to 3500 K through a nozzle. The tungsten gas chamber of the HFG is heated up to a desired temperature by a 60 kW optical power beam source. This system consists of an optical power source, a thermal chamber, an expansion nozzle, a test section, and an 80 cu m vacuum tank. 60 kW optical input power is obtained from the 150 kW Vortek arc lamp system (by Vortek Industries, Vancouver, Canada). This optical beam is focused to heat the gas chamber within which a flow media is heated. The maximum achievable temperature of the flow medium reached approximately 3500 K or even higher but is limited by the melting point of the chamber material used. The exhaust velocity through the nozzle was determined by the stagnation temperature and the molecular weight of the working medium at the test section. To provide design parameters, a NASA Chemical Equilibrium with Application (CEA) computer program is used for the simulation of aerothermal data. This CEA program can calculate chemical equilibrium and properties of complex mixtures using shock tube parameters. For nitrogen gas at 2666 K stagnation temperature, the maximum achievable velocity at the test section is approximately 2.45 km/sec which is within the range of the thermal velocity of 8000 K shock layer. Based on the calculation through the CEA program, the design parameters of a HFG were determined and implemented for the test section that includes an expansion nozzle. The installed test section of the experimental facility can sustain a condition of a re-entry vehicle from the Space at an altitude of 60-90 km. After installation of the HFG, the system was fully tested and its operational parameters were measured. An 80 cu m vacuum chamber of HFG was set at 1 torr level to keep a stable downstream condition. The pumping time to reach the minimum vacuum pressure (~ 1 torr) at the test chamber from atmospheric pressure was approximately an hour using Kinney (MBV-14000/MB -1600/KT-300) and Stokes (Model 1772 and 412) pumps. Such a setup condition allowed a continued stable operation of the HFG experiment with flowrates through 1-, 3-, or 5-mm diameters of nozzle throat. The flow characteristics of the HFG for various operating conditions were performed using a focused Schlieren method. At 0.8 torr chamber pressure, a barrel shock was observed at the test section. With a sphere obstacle of 12 mm diameter in the flow, a bow shock (~ 2-mm thickness) was observed by a focused Schlieren visualization method.

Hypervelocity flow↗

NASA NTRS1993

Application of CFD Analysis to Design Support and Problem Resolution for ASRM and RSRM

The use of Navier-Stokes CFD codes to predict the internal flow field environment in a solid rocket motor is a very important analysis element during the design phase of a motor development program. These computational flow field solutions uncover a variety of potential problems associated with motor performance as well as suggesting solutions to these problems. CFD codes have also proven to be of great benefit in explaining problems associated with operational motors such as in the case of the pressure spike problem with the STS-54B flight motor. This paper presents results from analyses involving both motor design support and problem resolution. The issues discussed include the fluid dynamic/mechanical stress coupling at field joints relative to significant propellant deformations, the prediction of axial and radial pressure gradients in the motor associated with motor performance and propellant mechanical loading, the prediction of transition of the internal flow in the motor associated with erosive burning, the accumulation of slag at the field joints and in the submerged nozzle region, impingement of flow on the nozzle nose, and pressure gradients in the nozzle region of the motor. The analyses presented in this paper have been performed using a two-dimensional axisymmetric model. Fluent/BFC, a three dimensional Navier-Stokes flow field code, has been used to make the numerical calculations. This code utilizes a staggered grid formulation along with the SIMPLER numerical pressure-velocity coupling algorithm. Wall functions are used to represent the character of the viscous sub-layer flow, and an adjusted k-epsilon turbulence model especially configured for mass injection internal flows, is used to model the growth of turbulence in the motor port. Conclusions discussed in this paper consider flow field effects on the forward, center, and aft propellant grains except for the head end star grain region of the forward propellant segment. The field joints and the submerged nozzle are discussed as well. Conclusions relative to both the design evaluation of the ASRM and the RSRM scenarios explaining the pressure spikes were based on the flow field solutions presented in this paper.

Dill, Richard A.↗

NASA NTRS2003

Pulsed Ejector Wave Propogation Test Program

The development of, and initial test data from, a nondetonating Pulse Detonation Engine (PDE) simulator tested in the NASA Glenn 1 x 1 foot Supersonic Wind Tunnel (SWT) is presented in this paper. The concept is a pulsed ejector driven by the simulated exhaust of a PDE. This pro- gram is applicable to a PDE entombed in a ramjet flowpath, i.e., a PDE combined-cycle propulsion system. The ejector primary flow is a pulsed, uiiderexpanded, supersonic nozzle simulating the supersonic waves ema- nating from a PDE, while the ejector secondary flow is the 1 x 1 foot SWT test section operated at subsonic Mach numbers. The objective is not to study the detonation details, but the wave physics including t,he start- ing vortices, the extent of propagation of the wave front, the reflection of the wave from the secondary flowpath walls, and the timing of these events of a pulsed ejector, and correlate these with Computational Fluid Dynamics (CFD) code predictions. Pulsed ejectors have been shown to result in a 3 to 1 improvement in LID (length-to-diameter) and a near 2 to 1 improvement in thrust augmentation over a steady ejector. This program will also explore the extent of upstream interactions between an inlet and large, periodically applied, backpressures to the inlet as would be present due to combustion tube detonations in a PDE. These interactions could result in inlet unstart or buzz for a supersonic mixed compression inlet. The design of the present experiment entailed the use of an 2-t diagram characteristics code to study the nozzle filling and purging timescales as well as a series of CFD analyses conducted using the WIND code. The WIND code is a general purpose CFD code for solution of the Reynolds averaged Navier-Stokes equations and can be applied to both steady state and time-accurate calculations. The first, proof-of-concept, test entry (spring 2001) pressure distributions shown here indicate the simulation concept was successful and therefore the experimental approach is sound.

Fernandez, Rene↗

NASA NTRS1988

CFD prediction of the reacting flow field inside a subscale scramjet combustor

A three-dimensional, Reynolds-averaged Navier-Stokes CFD code has been used to calculate the reacting flowfield inside a hydrogen-fueled, subscale scramjet combustor. Pilot fuel was injected transversely upstream of the combustor and the primary fuel was injected transversely downstream of a backward facing step. A finite rate combustion model with two-step kinetics was used. The CFD code used the explicit MacCormack algorithm with point-implicit treatment of the chemistry source terms. Turbulent mixing of the jets with the airstream was simulated by a simple mixing length scheme, whereas near wall turbulence was accounted for by the Baldwin-Lomax model. Computed results were compared with experimental wall pressure measurements.

Chitsomboon, T.↗

NASA NTRS2004

Rotor Airloads Prediction Using Loose Aerodynamic Structural Coupling

This work couples a computational fluid dynamics (CFD) code and rotorcraft computational structural dynamics (CSD) code to calculate helicopter rotor airloads across a range of flight conditions. An iterative loose (weak) coupling methodology is used to couple the CFD and CSD codes on a per revolution, periodic basis. The CFD uses a high fidelity, Navier-Stokes, overset grid methodology with first principles-based wake capturing. Modifications are made to the CFD code for aeroelastic analysis. For a UH-60A Blackhawk helicopter, four challenging level flight conditions are computed: 1) low speed (u = 0.15) with blade-vortex interaction, 2) high speed (u = 0.37) with advancing blade negative lift, 3) high thrust with dynamic stall (u = 0.24), and 4) hover. Results are compared with UH-60A Airloads Program fight test data. Most importantly, for all cases the loose coupling methodology is shown to be stable, convergent, and robust with full coupling of normal force, pitching moment, and chord force. In comparison with flight test data, normal force and pitching moment magnitudes are in good agreement. For the high speed and dynamic stall cases a phase lag in comparison with the data is seen, nonetheless, the shapes of the curves are very good. Overall, the results are noteworthy improvement over lifting line aerodynamics used in rotorcraft comprehensive codes.

Potsdam, Mark↗

NASA NTRS2004

Propulsion Simulations Using Advanced Turbulence Models with the Unstructured Grid CFD Tool, TetrUSS

A computational investigation has been completed to assess the capability of TetrUSS for exhaust nozzle flows. Three configurations were chosen for this study (1) an axisymmetric supersonic jet, (2) a transonic axisymmetric boattail with solid sting operated at different Reynolds number and Mach number, and (3) an isolated non-axisymmetric nacelle with a supersonic cruise nozzle. These configurations were chosen because existing experimental data provided a means for measuring the ability of TetrUSS for simulating complex nozzle flows. The main objective of this paper is to validate the implementation of advanced two-equation turbulence models in the unstructured-grid CFD code USM3D for propulsion flow cases. USM3D is the flow solver of the TetrUSS system. Three different turbulence models, namely, Menter Shear Stress Transport (SST), basic k epsilon, and the Spalart-Allmaras (SA) are used in the present study. The results are generally in agreement with other implementations of these models in structured-grid CFD codes. Results indicate that USM3D provides accurate simulations for complex aerodynamic configurations with propulsion integration.

Abdol-Hamid, Khaled S.↗

NASA NTRS1993

An experimental study of characteristic combustion-driven flows for CFD validation

The application of laser-based diagnostic techniques has become commonplace to a wide variety of combustion problems. New insights into combustion phenomena at a level previously unattainable has been made possible by non-intrusive measurements of velocity, temperature, and species. However, due to the adverse conditions which exist inside rocket engines, relatively few studies have addressed these combustion environments. The high pressure, high speed, combusting environment in a rocket engine prohibits the application of several measurement techniques. However, in the rocket community, there is a critical need for rocket flow field data to validate computational fluid dynamic (CFD) codes. Currently at Penn State, there is an effort to obtain flowfield measurements inside a rocket engine. Velocity measurements have been made inside the combustion chamber of a uni-element (shear coaxial injector) optically accessible rocket chamber at several axial locations downstream of the injector. These measurements, combined with future measurements, will provide benchmark data for CFD code validation.

Pal, S.↗

NASA NTRS1987

Duct flow nonuniformities for Space Shuttle Main Engine (SSME)

A three-duct Space Shuttle Main Engine (SSME) Hot Gas Manifold geometry code was developed for use. The methodology of the program is described, recommendations on its implementation made, and an input guide, input deck listing, and a source code listing provided. The code listing is strewn with an abundance of comments to assist the user in following its development and logic. A working source deck will be provided. A thorough analysis was made of the proper boundary conditions and chemistry kinetics necessary for an accurate computational analysis of the flow environment in the SSME fuel side preburner chamber during the initial startup transient. Pertinent results were presented to facilitate incorporation of these findings into an appropriate CFD code. The computation must be a turbulent computation, since the flow field turbulent mixing will have a profound effect on the chemistry. Because of the additional equations demanded by the chemistry model it is recommended that for expediency a simple algebraic mixing length model be adopted. Performing this computation for all or selected time intervals of the startup time will require an abundance of computer CPU time regardless of the specific CFD code selected.

Source record↗

NASA NTRS2001

An Experimental and CFD Study of a Supersonic Coaxial Jet

A supersonic coaxial jet facility is designed and experimental data are acquired suitable for the validation of CFD codes employed in the analysis of high-speed air-breathing engines. The center jet is of a light gas, the coflow jet is of air, and the mixing layer between them is compressible. The jet flow field is characterized using schlieren imaging, surveys with pitot, total temperature and gas sampling probes, and RELIEF velocimetry. VULCAN, a structured grid CFD code, is used to solve for the nozzle and jet flow, and the results are compared to the experiment for several variations of the kappa - omega turbulence model

Cutler, A. D.↗

NASA NTRS1996

Aeroelastic Calculations Using CFD for a Typical Business Jet Model

Two time-accurate Computational Fluid Dynamics (CFD) codes were used to compute several flutter points for a typical business jet model. The model consisted of a rigid fuselage with a flexible semispan wing and was tested in the Transonic Dynamics Tunnel at NASA Langley Research Center where experimental flutter data were obtained from M(sub infinity) = 0.628 to M(sub infinity) = 0.888. The computational results were computed using CFD codes based on the inviscid TSD equation (CAP-TSD) and the Euler/Navier-Stokes equations (CFL3D-AE). Comparisons are made between analytical results and with experiment where appropriate. The results presented here show that the Navier-Stokes method is required near the transonic dip due to the strong viscous effects while the TSD and Euler methods used here provide good results at the lower Mach numbers.

Gibbons, Michael D.↗

NASA NTRS2019

SINDA/FLUINT and Thermal Desktop Multi-Node Settled and Unsettled Propellant Tank Modeling of Zero Boil Off Test

Cryogenic propellant storage tank self-pressurization involves complex physical phenomena which are usually analytically modelled via complex multidimensional CFD codes. Unfortunately these codes, even when modelling axisymmetric domains, may takes weeks or longer to obtain transient pressure and temperature information for relatively short periods of time (several seconds to several hours). Propellant tank storage end-to-end mission simulations can last a duration of days to weeks to months. Multi-node modelling of propellant tanks is a viable alternative to traditional CFD modelling and presents the advantage of greatly reduced run times on the order of hours and days compared to the weeks or longer for CFD codes. A multi-node model represents the fluid within the storage tank, as well as the storage tank itself, as a fluid-thermal network. This type of setup is not necessarily geometrically based. This can be accomplished using a commercial generalized fluid-thermal network code, such as SINDA/FLUINT (SF). The advantage of using a fluid-thermal network code like SF lies in its extensive ability to model the external environment of the storage tank through the graphical user interface, Thermal Desktop (TD). The total heat load into the tank may be a function of heaters and a complex radiative environment as well. Thermal Desktop may be used to address the detailed radiative environment of the tank as well as building a geometrically accurate depiction of the storage tank itself.

Sakowski, Barbara↗

NASA NTRS1994

Towards Understanding the Fluid Dynamic Phenomenon of Interest to Rocket Base Heating: A Review

The significance of the base heating problem for rockets during ascent is due to the complex interaction between the rocket nozzle plumes and the external-flow which can change the flow characteristics in the base region dramatically. At lower altitudes the external-flow merges with the plume-flow, without the formation of a large separated flow region, and the cooler external-flow promotes convective cooling of the base wall. Under these conditions the majority of the base heating is due to radiative heating from the shock heated plume gases. At higher altitudes, however, the process of base heating is not so straightforward. The plume and the base flow expands dramatically and separated flow regions occur in the base area. Hot exhaust gases from the rocket nozzle will be entrained into the separated flow regions and produce a convective component to the base wall heating. Further, if the rocket exhaust-gas contains soot, the soot can increase the emission from the gas and dramatically increase the wall absorption coefficient for radiative heating if it is deposited on the walls . In addition, if the rocket exhaust gas is fuel rich, the fuel can bum in the separated flow regions and further increase the base heating. The base burning phenomenon, and the increased base heating caused by it at higher altitudes, have been observed for the Space Shuttle and Saturn Rocket. Under these conditions, the total heating is significantly higher than the heating without separated flow in the base region, and the increase in heating is directly attributable to the fluid dynamic complexity of the base region. Realistic simulation of the base heating requires that the calculated flow environment reproduce the fluid dynamic flow features accurately. Thus, it will be necessary to introduce into the CFD codes the capability for the flow to respond to the complex vehicle geometry, the effect of turbulence, the ability to accurately reproduce the plume shock/shear layer structures and capture such phenomenon as shock induced base separation and base-burning phenomenon. A survey of experimental, theoretical and computational work that details the fluid dynamics of the base flow environment will be presented in the proposed paper. CFD simulations of rocket base flows using standard CFD codes such as OVERFLOW or GASP will be explored to capture these phenomenon accurately. Merits and limitations of these codes for base flow environment predictions will be explored.

Venkatapathy, E.↗

NASA NTRS2002

Fundamental Mixing and Combustion Experiments for Propelled Hypersonic Flight

Two experiments have been conducted to acquire data for the validation of computational fluid dynamics (CFD) codes used in the design of supersonic combustors. The first experiment is a study of a supersonic coaxial jet into stagnant air in which the center jet is of a light gas, the coflow jet is of air, and the mixing layer between them is compressible. The jet flow field is characterized using schlieren imaging, surveys with Pitot, total temperature and gas sampling probes, and RELIEF velocimetry. VULCAN, a structured grid CFD code, is used to solve for the nozzle and jet flow. The second experiment is a study of a supersonic combustor consisting of a diverging duct with single downstream-angled wall injector. Entrance Mach number is 2 and enthalpy is nominally that of Mach 7 flight. Coherent anti-Stokes Raman spectroscopy (CARS) has been used to obtain nitrogen temperature in planes of the flow, and surface pressures and temperatures have also been acquired. Modern-design-of-experiment techniques have been used to maximize the quality of the data set.

Cutler, A. D.↗

NASA NTRS2002

A Modified Wall Matching Treatment to Account for Local Solid to Fluid Thermal Coupling

The wall-matching methodology of Wilcox is modified to include a solid-wall, thermal-conduction model. This coupled fluid-thermal-structure model is derived assuming that the wall thermal-structure behavior is locally one-dimensional and that structural deformations, due to thermally induced stresses, are not significant. The one-dimensional coupled fluid-thermal-structure model is derived such that the wall temperature is removed as an independent boundary condition variable. The one-dimensional coupled fluid-thermal-structure model is also derived for the general case of an arbitrary mixture of thermally prefect gases and a wall of arbitrary thickness and conductivity by using a compressible, streamwise-pressure-gradient-corrected, wall-matching function and Fourier's law of heat conduction. The resulting model was implemented in the VULCAN CFD code as a new boundary condition type. VULCAN was then used to simulate a two-dimensional Mach 6 wind tunnel facility nozzle flow to demonstrate/validate the one-dimensional coupled fluid-thermal-structure model. The nozzle internal-wall surface temperature and heat transfer distributions computed using the one-dimensional coupled fluid-thermal-structure model are compared to wall temperature and heat transfer distributions from an iterative multi-dimensional analysis obtained by coupling the VULCAN CFD code and the MSC/NASTRAN-thermal code. The one-dimensional coupled fluid-thermal-structure model analysis is shown to be very robust and in excellent agreement with the multi-dimensional iteratively coupled analysis. It is also shown that the one-dimensional analysis can be used as an initial guess for the multi-dimensional iteratively coupled analysis.

White, Jeffery A.↗

NASA NTRS2002

A Modified Wall Matching Treatment to Account for Local Solid to Fluid Thermal Coupling

White, Jeffery A.↗

NASA NTRS2010

Numerical Simulations of the Boundary Layer Transition Flight Experiment

Computational Fluid Dynamics (CFD) simulations were used to study the possible effects that the Boundary Layer Transition (BLT) Flight Experiments may have on the heating environment of the Space Shuttle during its entry to Earth. To investigate this issue, hypersonic calculations using the Data-Parallel Line Relaxation (DPLR) and Langley Aerothermodynamic Upwind Relaxation (LAURA) CFD codes were computed for a 0.75 tall protuberance at flight conditions of Mach 15 and 18. These initial results showed high surface heating on the BLT trip and the areas surrounding the protuberance. Since the predicted peak heating rates would exceed the thermal limits of the materials selected to construct the BLT trip, many changes to the geometry were attempted in order to reduce the surface heat flux. The following paper describes the various geometry revisions and the resulting heating environments predicted by the CFD codes.

Tang, Chun Y.↗

NASA NTRS1988

A computational study of heat transfer for laminar hypervelocity flows

Computational Fluid Dynamics (CFD) codes are routinely used to predict the flowfield and the heating environment around complex reentry configurations. At hypervelocities, where the velocity is greater than 3 km/sec, the AFWAL version of the blunt body code predicts the correct surface pressure distributions but underpredicts laminar wall heat fluxes. This study was performed to determine the reasons for the underprediction. The computer code chosen solves thin-layer Navier-Stokes equations in a time-asymptotic manner and assumes a constant isentropic exponent. Flowfields around a spherical configuration at various entry velocities are computed. The computed pressure distributions agree well with the tabulated, inviscid results of Lyubimov and Rusanov for entry velocities ranging from 0.6 to 5.92 km/sec. At hypervelocities, the calculated stagnation point heat transfer rates were lower by roughly fifty percent when compared to engineering correlations available in the literature. Good comparisons between heat transfer rates are obtained at hypervelocity entry conditions provided the CFD code is modified to include equilibrium air properties.

Balakrishnan, A.↗

NASA NTRS1993

A CFD-based aerodynamic design procedure for hypersonic wind-tunnel nozzles

A new procedure which unifies the best of current classical design practices, computational fluid dynamics (CFD), and optimization procedures is demonstrated for designing the aerodynamic lines of hypersonic wind-tunnel nozzles. The new procedure can be used to design hypersonic wind tunnel nozzles with thick boundary layers where the classical design procedure has been shown to break down. An efficient CFD code, which solves the parabolized Navier-Stokes (PNS) equations using an explicit upwind algorithm, is coupled to a least-squares (LS) optimization procedure. A LS problem is formulated to minimize the difference between the computed flow field and the objective function, consisting of the centerline Mach number distribution and the exit Mach number and flow angle profiles. The aerodynamic lines of the nozzle are defined using a cubic spline, the slopes of which are optimized with the design procedure. The advantages of the new procedure are that it allows full use of powerful CFD codes in the design process, solves an optimization problem to determine the new contour, can be used to design new nozzles or improve sections of existing nozzles, and automatically compensates the nozzle contour for viscous effects as part of the unified design procedure. The new procedure is demonstrated by designing two Mach 15, a Mach 12, and a Mach 18 helium nozzles. The flexibility of the procedure is demonstrated by designing the two Mach 15 nozzles using different constraints, the first nozzle for a fixed length and exit diameter and the second nozzle for a fixed length and throat diameter. The computed flow field for the Mach 15 least squares parabolized Navier-Stokes (LS/PNS) designed nozzle is compared with the classically designed nozzle and demonstrates a significant improvement in the flow expansion process and uniform core region.

Korte, John J.↗