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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12

Impeller shroud to casing leakage flow simulations in the Space Shuttle Main Engine high pressure fuel pump

Quasi-three-dimensional Navier-Stokes calculations were carried out for the Space Shuttle Main Engine high-pressure fuel pump to simulate the impeller shroud to casing leakage flow. This flow geometry was modeled as an axisymmetric cavity flow with a stationary surface representing the casing, and a rotating surface denoting the impeller. A 63 x 81-node mesh provided sufficient resolution in the regions of greatest flow variations and reduced the effects of numerical diffusion. The turbulence field was closed with the high Reynolds number form of the k-epsilon model supplemented with wall functions in the vicinity of the walls. Finally, a parametric study quantified the effects of through mass flow changes on this leakage flow.

Sindir, Munir M.↗

Space Shuttle Main Engine radio frequency emissions

Several approaches to develop a diagnostics system for monitoring the operational health of the Space Shuttle Main Engine (SSME) are being evaluated. The ultimate goal is providing protection for the SSME as well as improving ground and flight test techniques. One scenario with some potential is measuring radio frequency (RF) emissions (if present) in the exhaust plume and correlating the data to engine health. An RF emissions detection system was therefore designed, the equipment leased, and the components integrated and checked out to conduct a quick-look investigation of RF emissions in the SSME exhaust plume. The system was installed on the A-1 Test Stand at Stennis Space Center, MS, and data were successfully acquired during SSME firings from May 3 to September 15, 1988. The experiments indicated that emitted radiation in the RF (20 to 470 MHz) spectrum definitely exists in the SSME exhaust plume, and is of such magnitude that it can be distinguished during the firing from background noise. Although additional efforts are necessary to assess the merit of this approach as a health monitoring technique, the potential is significant, and additional studies are recommended.

Rester, A. W.↗

Fault diagnosis for the Space Shuttle main engine

A conceptual design of a model-based fault detection and diagnosis system is developed for the Space Shuttle main engine. The design approach consists of process modeling, residual generation, and fault detection and diagnosis. The engine is modeled using a discrete time, quasilinear state-space representation. Model parameters are determined by identification. Residuals generated from the model are used by a neural network to detect and diagnose engine component faults. Fault diagnosis is accomplished by training the neural network to recognize the pattern of the respective fault signatures. Preliminary results for a failed valve, generated using a full, nonlinear simulation of the engine, are presented. These results indicate that the developed approach can be used for fault detection and diagnosis. The results also show that the developed model is an accurate and reliable predictor of the highly nonlinear and very complex engine.

Duyar, Ahmet↗

Phased Array Ultrasonic Evaluation of Space Shuttle Main Engine (SSME) Nozzle Weld

This viewgraph presentation gives an overview of the phased array ultrasonic evaluation of the Space Shuttle Main Engine (SSME) nozzle weld. Details are given on the nondestructive testing evaluation approach, conventional shear wave and phased array techniques, and an x-ray versus phased array risk analysis. The field set-up was duplicated to the greatest extent possible in the laboratory and the phased array ultrasonic technique was developed and validated prior to weld evaluation. Results are shown for the phased array ultrasonic evaluation and conventional ultrasonic evaluation results.

James, Steve↗

Maintainability of the Space Shuttle Orbiter main engine.

Review of the long-life and minimum-turnaround-maintenance features in the design of the Space Shuttle Orbiter main engine aimed at reducing the latter's field operating costs. These features include the regeneratively cooled hot-gas system selected, the provision of additional fatigue margins in the design of rotating machinery elements, and employment of a proven approach to engine condition monitoring for fault detection and identification.

Goe, R. T.↗

Update on the development of the Space Shuttle main engine /as of June 20, 1978/

During the last year, significant progress was made toward the development of the Space Shuttle Main Engine which will provide propulsion for the Space Shuttle Orbiter Vehicle. Component and subsystem testing was conducted at the Rocketdyne Santa Susana Field Laboratory on combustion devices, turbomachinery, and the engine POGO suppression system. Engine testing continued at the National Space Technology Laboratories on both single engines and a three-engine cluster. As a result of these tests, hardware limitations were identified and design modifications were incorporated and evaluated by further testing. Current effort is being directed toward the delivery of the first flight engines and certification of the SSME for manned flight.

Johnson, J. R.↗

Space Shuttle Main Engine Off-Nominal Low Power Level Operation

This paper describes Rocketdyne's successful analysis and demonstration of the Space Shuttle Main Engine (SSME) operation at off-nominal power levels during Reusable Launch Vehicle (RLV) evaluation tests. The nominal power level range for the SSME is from 65% rated power level (RPL) to 109% RPL. Off-nominal power levels incrementally demonstrated were: 17% RPL, 22% RPL, 27% RPL, 40% RPL, 45% RPL, and 50% RPL. Additional achievements during low power operation included: use of a hydrostatic bearing High Pressure Oxidizer Turbopump (HPOTP), nominal High Pressure Fuel Turbopump (HPFTP) first rotor critical speed operation, combustion stability at low power levels, and refined definition of nozzle flow separation heat loads.

Bradley, Michael↗

Thermographic Nondestructive Evaluation of the Space Shuttle Main Engine Nozzle

The methods and results presented in this summary address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Walker, James L.↗

Thermographic/Nondestructive Evaluation of the Space Shuttle Main Engine Nozzle

The methods and results presented in this summary address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner 'hot wall' surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Walker, J. L.↗

Space Shuttle Main Engine Quantitative Risk Assessment: Illustrating Modeling of a Complex System with a New QRA Software Package

During 1997, a team from Hernandez Engineering, MSFC, Rocketdyne, Thiokol, Pratt & Whitney, and USBI completed the first phase of a two year Quantitative Risk Assessment (QRA) of the Space Shuttle. The models for the Shuttle systems were entered and analyzed by a new QRA software package. This system, termed the Quantitative Risk Assessment System(QRAS), was designed by NASA and programmed by the University of Maryland. The software is a groundbreaking PC-based risk assessment package that allows the user to model complex systems in a hierarchical fashion. Features of the software include the ability to easily select quantifications of failure modes, draw Event Sequence Diagrams(ESDs) interactively, perform uncertainty and sensitivity analysis, and document the modeling. This paper illustrates both the approach used in modeling and the particular features of the software package. The software is general and can be used in a QRA of any complex engineered system. The author is the project lead for the modeling of the Space Shuttle Main Engines (SSMEs), and this paper focuses on the modeling completed for the SSMEs during 1997. In particular, the groundrules for the study, the databases used, the way in which ESDs were used to model catastrophic failure of the SSMES, the methods used to quantify the failure rates, and how QRAS was used in the modeling effort are discussed. Groundrules were necessary to limit the scope of such a complex study, especially with regard to a liquid rocket engine such as the SSME, which can be shut down after ignition either on the pad or in flight. The SSME was divided into its constituent components and subsystems. These were ranked on the basis of the possibility of being upgraded and risk of catastrophic failure. Once this was done the Shuttle program Hazard Analysis and Failure Modes and Effects Analysis (FMEA) were used to create a list of potential failure modes to be modeled. The groundrules and other criteria were used to screen out the many failure modes that did not contribute significantly to the catastrophic risk. The Hazard Analysis and FMEA for the SSME were also used to build ESDs that show the chain of events leading from the failure mode occurence to one of the following end states: catastrophic failure, engine shutdown, or siccessful operation( successful with respect to the failure mode under consideration).

Smart, Christian↗

Design overview of fiber-reinforced superalloy composites for the Space Shuttle main engine

This preliminary design study evaluated the potential of fiber-reinforced superalloys (FRS) for hot-section components of Space Shuttle Main Engine turbopumps. Emphasis was placed on uncooled turbine blades, with a more limited evaluation of FRS turbine stator vanes. The study included FRS properties evaluation, current structural design capability, and preliminary design and structural analysis. In addition, key technology needs were identified, and a plan was generated to develop operational hardware for advanced versions of the SSME. Based on projections of design properties for FRS composites comprising 50 volume percent of W-4Re-0.38Hf-0.02C wire filaments in a ductile superalloy matrix, it was concluded that FRS turbine blades offer the potential of significant improved operating life and higher temperature capability over the MAR-M-246(Hf) (DS) blades currently used in the SSME.

Lewis, J. R.↗

Thermal finite-element analysis of space shuttle main engine turbine blade

Finite-element, transient heat transfer analyses were performed for the first-stage blades of the space shuttle main engine (SSME) high-pressure fuel turbopump. The analyses were based on test engine data provided by Rocketdyne. Heat transfer coefficients were predicted by performing a boundary-layer analysis at steady-state conditions with the STAN5 boundary-layer code. Two different peak-temperature overshoots were evaluated for the startup transient. Cutoff transient conditions were also analyzed. A reduced gas temperature profile based on actual thermocouple data was also considered. Transient heat transfer analyses were conducted with the MARC finite-element computer code.

Abdul-Aziz, Ali↗

Use of an expert system data analysis manager for space shuttle main engine test evaluation

The ability to articulate, collect, and automate the application of the expertise needed for the analysis of space shuttle main engine (SSME) test data would be of great benefit to NASA liquid rocket engine experts. This paper describes a project whose goal is to build a rule-based expert system which incorporates such expertise. Experiential expertise, collected directly from the experts currently involved in SSME data analysis, is used to build a rule base to identify engine anomalies similar to those analyzed previously. Additionally, an alternate method of expertise capture is being explored. This method would generate rules inductively based on calculations made using a theoretical model of the SSME's operation. The latter rules would be capable of diagnosing anomalies which may not have appeared before, but whose effects can be predicted by the theoretical model.

Abernethy, Ken↗

Space Shuttle Main Engine instrumented High Pressure Oxidizer Turbopump technology test bed testing results summary

This paper presents the test results from the Space Shuttle Main Engine (SSME) instrumented High Pressure Oxidizer Turbopump (HPOTP). The turbopump was tested on Engine 3001, a highly instrumented engine, in an effort to characterize the turbopump and the engine system. Seven tests, for a total duration of 766 seconds, were performed over a five month time period. The testing was performed at a wide variety of engine conditions. Changes in engine mixture ratio, power level, engine inlet oxidizer pressure, engine inlet fuel pressure, and engine start sequence were made. A discussion of all the HPOTP pressure and temperature data obtained are presented with comparisons to supporting analyses made where applicable. The effect of the various engine conditions on the measured data is addressed. This paper also discusses the challenges that were overcome to obtain the data. The significant instrumentation related problems encountered during the design, fabrication, and testing of this turbopump are summarized. Only those issues that affected the data obtained or the instrumentation itself are discussed. The relevance of the data to other noninstrumented turbomachinery is outlined. Conclusions and recommendations resulting from the test series will be presented.

Koelbl, Mary E.↗

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↗

A Navier-Stokes flow simulation of the Space Shuttle Main Engine Hot Gas Manifold

Incompressible viscous flow inside the turnaround duct, the fuel bowl, the transfer duct and the racetrack of the Space Shuttle Main Engine (SSME) Hot Gas Manifold (HGM) has been computed using the method of pseudo-compressibility together with an implicit, approximate-factorization algorithm. A multiple-zone method is used to make solution of flows in complex geometries easy. A model which predicts the pressure loading for the shield and the injector post arrangement without solving the complex flow field in the main injector region is proposed. The computed results show good qualitative agreement with experimental data.

Yang, Ruey-Jen↗

Computational fluid dynamics as a design tool for the hot gas manifold of the Space Shuttle Main Engine

The paper discusses the application of computational fluid dynamics as a design tool for the Hot Gas Manifold of the Space Shuttle Main Engine. An improved Hot Gas Manifold configuration was arrived at computationally. This configuration was then built and air flow tested. Testing verified this configuration to be a substantial improvement over existing flight designs.

Ziebarth, J. P.↗

Evaluation and Improvement of Liquid Propellant Rocket Chugging Analysis Techniques. Part 1: A One-Dimensional Analysis of Low Frequency Combustion Instability in the Fuel Preburner of the Space Shuttle Main Engine

Low frequency combustion instability, known as chugging, is consistently experienced during shutdown in the fuel and oxidizer preburners of the Space Shuttle Main Engines. Such problems always occur during the helium purge of the residual oxidizer from the preburner manifolds during the shutdown sequence. Possible causes and triggering mechanisms are analyzed and details in modeling the fuel preburner chug are presented. A linearized chugging model, based on the foundation of previous models, capable of predicting the chug occurrence is discussed and the predicted results are presented and compared to experimental work performed by NASA. Sensitivity parameters such as chamber pressure, fuel and oxidizer temperatures, and the effective bulk modulus of the liquid oxidizer are considered in analyzing the fuel preburner chug. The computer program CHUGTEST is utilized to generate the stability boundary for each sensitivity study and the region for stable operation is identified.

Lim, Kair Chuan↗