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NASA NTRS2013

Acoustic Characterization of Compact Jet Engine Simulator Units

Two dual-stream, heated jet, Compact Jet Engine Simulator (CJES) units are designed for wind tunnel acoustic experiments involving a Hybrid Wing Body (HWB) vehicle. The newly fabricated CJES units are characterized with a series of acoustic and flowfield investigations to ensure successful operation with minimal rig noise. To limit simulator size, consistent with a 5.8% HWB model, the CJES units adapt Ultra Compact Combustor (UCC) technology developed at the Air Force Research Laboratory. Stable and controllable operation of the combustor is demonstrated using passive swirl air injection and backpressuring of the combustion chamber. Combustion instability tones are eliminated using nonuniform flow conditioners in conjunction with upstream screens. Through proper flow conditioning, rig noise is reduced by more than 20 dB over a broad spectral range, but it is not completely eliminated at high frequencies. The low-noise chevron nozzle concept designed for the HWB test shows expected acoustic benefits when installed on the CJES unit, and consistency between CJES units is shown to be within 0.5 dB OASPL.

Doty, Michael J.↗

NASA NTRS1987

Conventionally cast and forged copper alloy for high-heat-flux thrust chambers

The combustion chamber liner of the space shuttle main engine is made of NARloy-Z, a copper-silver-zirconium alloy. This alloy was produced by vacuum melting and vacuum centrifugal casting; a production method that is currently now available. Using conventional melting, casting, and forging methods, NASA has produced an alloy of the same composition called NASA-Z. This report compares the composition, microstructure, tensile properties, low-cycle fatigue life, and hot-firing life of these two materials. The results show that the materials have similar characteristics.

Kazaroff, John M.↗

NASA NTRS2016

Design and Fabrication of Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged Combustion Thrust Chamber Injectors

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. On the current project, several configurations of new main injectors were considered for the thrust chamber assembly of the integrated test article. All the injector elements were of the gas-centered swirl coaxial type, similar to those used on the Russian oxidizer-rich staged-combustion rocket engines. In such elements, oxidizer-rich combustion products from the preburner/turbine exhaust flow through a straight tube, and fuel exiting from the combustion chamber and nozzle regenerative cooling circuits is injected near the exit of the oxidizer tube through tangentially oriented orifices that impart a swirl motion such that the fuel flows along the wall of the oxidizer tube in a thin film. In some elements there is an orifice at the inlet to the oxidizer tube, and in some elements there is a sleeve or "shield" inside the oxidizer tube where the fuel enters. In the current project, several variations of element geometries were created, including element size (i.e., number of elements or pattern density), the distance from the exit of the sleeve to the injector face, the width of the gap between the oxidizer tube inner wall and the outer wall of the sleeve, and excluding the sleeve entirely. This paper discusses the design rationale for each of these element variations, including hydraulic, structural, thermal, combustion performance, and combustion stability considerations. This paper also discusses the fabrication and assembly of the injector components, including the injector body/interpropellant plate, the additive manufactured GRCop-84 faceplate, and the pieces that make up the injector elements including the oxidizer tube, an inlet to the oxidizer tube, and a facenut that includes the fuel tangential inlets and forms the initial recessed volume where oxidizer and fuel first interact. Hot-fire test results of these main injector designs in an integrated test article that includes an oxidizer-rich preburner are described in companion papers at this JANNAF meeting.

Garcia, C. P.↗

NASA NTRS2000

Lean direct wall fuel injection method and devices

A fuel combustion chamber, and a method of and a nozzle for mixing liquid fuel and air in the fuel combustion chamber in lean direct injection combustion for advanced gas turbine engines, including aircraft engines. Liquid fuel in a form of jet is injected directly into a cylindrical combustion chamber from the combustion chamber wall surface in a direction opposite to the direction of the swirling air at an angle of from about 50.degree. to about 60.degree. with respect to a tangential line of the cylindrical combustion chamber and at a fuel-lean condition, with a liquid droplet momentum to air momentum ratio in the range of from about 0.05 to about 0.12. Advanced gas turbines benefit from lean direct wall injection combustion. The lean direct wall injection technique of the present invention provides fast, uniform, well-stirred mixing of fuel and air. In addition, in order to further improve combustion, the fuel can be injected at a venturi located in the combustion chamber at a point adjacent the air swirler.

Choi, Kyung J.↗

NASA NTRS1988

Evaluation and Improvement of Liquid Propellant Rocket Chugging Analysis Techniques. Part 2: a Study of Low Frequency Combustion Instability in Rocket Engine Preburners Using a Heterogeneous Stirred Tank Reactor Model

During the shutdown of the space shuttle main engine, oxygen flow is shut off from the fuel preburner and helium is used to push the residual oxygen into the combustion chamber. During this process a low frequency combustion instability, or chug, occurs. This chug has resulted in damage to the engine's augmented spark igniter due to backflow of the contents of the preburner combustion chamber into the oxidizer feed system. To determine possible causes and fixes for the chug, the fuel preburner was modeled as a heterogeneous stirred tank combustion chamber, a variable mass flow rate oxidizer feed system, a constant mass flow rate fuel feed system and an exit turbine. Within the combustion chamber gases were assumed perfectly mixed. To account for liquid in the combustion chamber, a uniform droplet distribution was assumed to exist in the chamber, with mean droplet diameter determined from an empirical relation. A computer program was written to integrate the resulting differential equations. Because chamber contents were assumed perfectly mixed, the fuel preburner model erroneously predicted that combustion would not take place during shutdown. The combustion rate model was modified to assume that all liquid oxygen that vaporized instantaneously combusted with fuel. Using this combustion model, the effect of engine parameters on chamber pressure oscillations during the SSME shutdown was calculated.

Bartrand, Timothy A.↗

NASA NTRS1937

Effects of Air-Fuel Spray and Flame Formation in a Compression-Ignition Engine

High-speed motion pictures were taken at the rate of 2,500 frames per second of the fuel spray and flame formation in the combustion chamber of the NACA combustion apparatus. The compression ratio was 13.2 and the speed 1,500 revolutions per minute. An optical indicator was used to record the time-pressure relationship in the combustion chamber. The air-fuel ratio was varied from 10.4 to 365. The results showed that as the air-fuel ratio was increased definite stratification of the charge occurred in the combustion chamber even though moderate air flow existed. The results also showed the rate of vapor diffusion to be relatively slow.

Rothrock, A M↗

NASA NTRS1995

Stabilization Of Combustion Of Sprayed Fuel

Several modifications of nozzle spraying liquid propellant into combustion chamber proposed to stabilize combustion. Proposed changes in design of nozzle alter flow field in combustion chamber, according to fluid-mechanical principles, in such way as to suppress oscillations. Various alternative nozzle configurations include bluff or toroidal body to generate turbulence. Other features helping to suppress oscillations include down-stream recirculation zones, baffles, and damping cavities. Similar modifications help to suppress oscillations in industrial combustion chambers and in commercial and domestic oil-burning furnaces.

Voecks, Gerald E.↗

NASA NTRS2005

AXISYMMETRIC, THROTTLEABLE NON-GIMBALLED ROCKET ENGINE

A rocket engine assembly is provided for a vertically launched rocket vehicle. A rocket engine housing of the assembly includes two or more combustion chambers each including an outlet end defining a sonic throat area. A propellant supply for the combustion chambers includes a throttling injector, associated with each of the combustion chambers and located opposite to sonic throat area, which injects the propellant into the associated combustion chamber. A modulator, which may form part of the injector, and which is controlled by a controller, modulates the flow rate of the propellant to the combustion chambers so that the chambers provide a vectorable net thrust. An expansion nozzle or body located downstream of the throat area provides expansion of the combustion gases produced by the combustion chambers so as to increase the net thrust.

Sackheim, Robert L.↗

NASA NTRS1991

Business not as usual

Typical design simplification ideas which reduce costs; combustion chamber design simplification; combustion chambers; castings vs. machined and welded forgings; automated inspection; and life cycle costs are outlined. This presentation is represented by viewgraphs.

Source record↗

NASA NTRS1995

High-Aspect-Ratio Cooling Channel Concept Tested in Lewis' Rocket Engine Test Facility

Rocket combustion chamber walls are exposed to the high-temperature environment caused by the combustion of propellants. Even with the walls actively cooled by the fuel, the hot gases can deteriorate the walls severely and limit any possibility for reusing the combustion chamber. For many years, the NASA Lewis Research Center has performed subscale investigations of potential improved cooling concepts to extend the life and reliability of the combustion chamber. Results from previous subscale tests have shown that, by increasing the coolant channel height-to-width aspect ratio, the rocket combustion chamber hot gas side wall temperature can be reduced by as much as 28 percent, without an increase in the coolant pressure drop. Recently, a series of experiments were completed in Lewis' Rocket Engine Test Facility (RETF) to validate the benefits of high aspect ratio cooling channels with a high-pressure, contoured rocket combustion chamber.

Source record↗

NASA NTRS1953

Experimental investigation of a lightweight rocket chamber

Experiments have been conducted with a jacketed rocket combustion chamber that was fabricated by hydraulic-forming from sheet metal. Rocket combustion chambers made by this method have been used successfully. Runs with these combustion chambers have been made at over-all heat-transfer rates 1.7 Btu per square inch per second with water cooling and also ammonia as a regenerative coolant.

ENGINES, ROCKET↗

NASA NTRS1989

Transpiration And Regenerative Cooling Of Rocket Engine

Transpiration cooling extends limits of performance. Addition of transpiration cooling to regeneratively-cooled rocket-engine combustion chamber proposed. Modification improves performance of engine by allowing use of higher chamber pressure. Throat section of combustion-chamber wall cooled by transpiration, while chamber and nozzle sections cooled by fluid flowing in closed channels. Concept applicable to advanced, high-performance terrestrial engines or some kinds of industrial combustion chambers. With proper design, cooling scheme makes possible to achieve higher chamber pressure and higher overall performance in smaller engine.

Obrien, Charles J.↗

NASA NTRS1947

Performance Charts for a Turbojet System

Convenient charts are presented for computing the thrust, fuel consumption, and other performance values of a turbojet system. These charts take into account the effects of ram pressure, compressor pressure ratio, ratio of combustion-chamber-outlet temperature to atmospheric temperature, compressor efficiency, turbine efficiency, combustion efficiency, discharge-nozzle coefficient, losses in total pressure in the inlet to the jet-propulsion unit and in the combustion chamber, and variation in specific heats with temperature. The principal performance charts show clearly the effects of the primary variables and correction charts provide the effects of the secondary variables. The performance of illustrative cases of turbojet systems is given. It is shown that maximum thrust per unit mass rate of air flow occurs at a lower compressor pressure ratio than minimum specific fuel consumption. The thrust per unit mass rate of air flow increases as the combustion-chamber discharge temperature increases. For minimum specific fuel consumption, however, an optimum combustion-chamber discharge temperature exists, which in some cases may be less than the limiting temperature imposed by the strength temperature characteristics of present materials.

CHARTS-PERFORMANCE-ENGINES, TURBOJET↗

NASA NTRS2018

Performance, Stability and Compatibility of Oxygen/RP-1 Multi-Element Oxidizer-Rich Staged-Combustion Injectors

In 2015 and 2016, the National Aeronautics and Space Administration Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/RP-1 propellant multi-element oxidizer-rich staged-combustion test article. The main objective was to provide thrust chamber combustion stability data as part of the Combustion Stability Tool Development program, although demonstration of performance and compatibility of oxidizer-rich main injectors was also important. Funding was provided by the Air Force Space and Missile Systems Center. Five configurations of main injectors were designed and fabricated, using conventional gas-centered swirl coaxial injector element designs generally similar to those used in oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines. Variations of element features included element size, recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. Ablative combustion chambers were fabricated based on hardware previously used at the NASA MSFC for testing at similar size and pressure. Existing oxygen/RP-1 oxidizer-rich subscale preburner injectors and hot gas ducts from a previous NASA-funded program were modified for use to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Testing of the resulting integrated test article - which included the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was conducted at Test Stand 116 at the East Test Area of the NASA MSFC. The test article was well instrumented with static and dynamic pressure, temperature, and vibration sensors. This paper presents and discusses all the hot-fire test results of the integrated test article thrust chamber. Eighteen successful hot-fire tests of the integrated rig were conducted. Testing was accomplished with all five of the injector element concepts. Main combustion chamber pressures ranged from 710 to 2350 psia, and main combustion chamber mixture ratios ranged from 2.47 to 2.87. A chamber barrier fuel film coolant of about 2% to 4% of the total fuel flow was used for most tests. Characteristic exhaust velocity efficiency excluding the influence of the fuel film cooling ranged from 91% to 98% of theoretical. All tests of the thrust chamber exhibited stable combustion, even down to 40% of nominal operating pressures. Compatibility of the injector face and combustion chamber walls was acceptable. This paper is a follow-on to publication of preliminary test data presented at the 2016 JANNAF Liquid Propulsion Subcommittee meeting.

Hulka, J. R.↗

DOE OSTI2025

Exploring the Effects of Varying Pre-Chamber Geometry in a Heavy-Duty Natural Gas Optical Engine under Dilution Conditions

Pre-chamber combustion is an advanced ignition strategy that has been shown to enhance spark ignition (SI) combustion stability in natural gas (NG) engines by providing distributed ignition sites from turbulent jets and enhancing main-chamber turbulence. Pre-chamber combustion has been proven especially advantageous compared to SI in ultra-lean and dilute operating conditions. This work involves experimental investigation of the effects of varying passive pre-chamber nozzle configuration on pre-chamber and main chamber combustion under simulated exhaust gas recirculation (EGR) dilution (0 and 20%) conditions in a heavy-duty, single-cylinder, optically accessible NG engine at stoichiometric fuel-air ratio. Pre-chamber nozzle configurations include four pre-chambers with constant nozzle area to pre-chamber volume ratio (A/V) with different nozzle sizes and orientations and one configuration with larger nozzles. The optical engine is operated in a skip-fire sequence consisting of 18 motored cycles followed by two consecutive fired cycles to elucidate the effect of combustion residuals (internal EGR) on combustion evolution. Pressure-based diagnostics are used to monitor pre-chamber and subsequent main chamber combustion, and optical diagnostics include high-speed OH* chemiluminescence to visualize the development of pre-chamber jets and the resulting ignition of the main chamber charge. Heat release analysis of the in-cylinder pressure data indicates that a faster pre-chamber pressure rise does not always translate into faster main-chamber combustion. The pre-chamber with the smallest nozzle diameter produced the highest pre-chamber pressure rise and fastest combustion under non-diluted conditions. However, dilution delays the main chamber ignition for smaller nozzles despite a comparable rise in pre-chamber pressure compared to configurations with larger nozzles. This effect is more pronounced for cycles with in-cylinder combustion residuals in addition to external dilution. Additionally, it was observed that pre-chambers with swirling nozzles have a faster pressure rise in the pre-chamber and main chamber under dilute conditions. Optical diagnostics suggest that the main reason for the delay between the pre-chamber pressure rise and main-chamber combustion lies in jet quenching and delayed re-ignition, which can even lead to misfire if jets emitted from small nozzles combined with dilution fail to re-ignite.

Dhotre, Akash [University Of Minnesota-Twin Cities↗

NASA NTRS1992

Numerical analysis of the hot-gas-side and coolant-side heat transfer in liquid rocket engine combustors

The objective of this paper are to develop a multidisciplinary computational methodology to predict the hot-gas-side and coolant-side heat transfer and to use it in parametric studies to recommend optimized design of the coolant channels for a regeneratively cooled liquid rocket engine combustor. An integrated numerical model which incorporates CFD for the hot-gas thermal environment, and thermal analysis for the liner and coolant channels, was developed. This integrated CFD/thermal model was validated by comparing predicted heat fluxes with those of hot-firing test and industrial design methods for a 40 k calorimeter thrust chamber and the Space Shuttle Main Engine Main Combustion Chamber. Parametric studies were performed for the Advanced Main Combustion Chamber to find a strategy for a proposed combustion chamber coolant channel design.

Wang, Ten-See↗

NASA NTRS1993

Optical flameout detector

A device has been developed which monitors the presence of a flame within a combustion chamber. The optical flameout detection system responds to gross changes in combustor light intensity, which is monitored in two spectral bands. A photomultiplier tube makes optical measurements in the ultraviolet portion of the spectrum, and a silicon photodiode covers the visible region. The detectors, located outside the combustion chamber, receive the light energy radiated from the combustion process through fiber optic probes designed to operate in a high pressure environment. The optical fibers are aimed diagonally through the center of the injector at the combustion chamber wall downstream of the injector. The probes observe events occurring within a narrow conical-shaped field of view so that the system can quickly detect longitudinal movement of the flame front away from the injector. If a change in intensity of the flame is detected, the fuel supply to the combustion chamber is shut off, limiting the amount of unburned fuel in the combustion chamber which could reignite.

Borg, Stephen E.↗

NASA NTRS1998

Optical Flameout Detector

A device has been developed which monitors the presence of a flame within a combustion chamber. The optical flameout detection system responds to gross changes in combustor light intensity which is monitored in two spectral bands. A photomultiplier tube makes optical measurements in the ultraviolet portion of the spectrum and a silicon photodiode covers the visible region. The detectors, located outside the combustion chamber, receive the light energy radiated from the combustion process through fiber optic probes designed to operate in a high pressure environment. The optical fibers are aimed diagonally through the center of the injector at the combustion chamber wall downstream of the injector. The probe observes events occurring within a narrow conical-shaped field of view so that the system can quickly detect longitudinal movement of the flame front away from the injector. If a change in intensity of the flame is detected, the fuel supply to the combustion chamber is shut off limiting the amount of unburned fuel in the combustion chamber which could reignite.

Borg, Stephen E.↗