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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Labyrinth Seal Flutter Analysis and Test Validation in Support of Robust Rocket Engine Design

High energy-density turbomachines, like the SSME turbopumps, utilize labyrinth seals, also referred to as knife-edge seals, to control leakage flow. The pressure drop for such seals is order of magnitude higher than comparable jet engine seals. This is aggravated by the requirement of tight clearances resulting in possible unfavorable fluid-structure interaction of the seal system (seal flutter). To demonstrate these characteristics, a benchmark case of a High Pressure Oxygen Turbopump (HPOTP) outlet Labyrinth seal was studied in detail. First, an analytical assessment of the seal stability was conducted using a Pratt & Whitney legacy seal flutter code. Sensitivity parameters including pressure drop, rotor-to-stator running clearances and cavity volumes were examined and modeling strategies established. Second, a concurrent experimental investigation was undertaken to validate the stability of the seal at the equivalent operating conditions of the pump. Actual pump hardware was used to construct the test rig, also referred to as the (Flutter Rig). The flutter rig did not include rotational effects or temperature. However, the use of Hydrogen gas at high inlet pressure provided good representation of the critical parameters affecting flutter especially the speed of sound. The flutter code predictions showed consistent trends in good agreement with the experimental data. The rig test program produced a stability threshold empirical parameter that separated operation with and without flutter. This empirical parameter was used to establish the seal build clearances to avoid flutter while providing the required cooling flow metering. The calibrated flutter code along with the empirical flutter parameter was used to redesign the baseline seal resulting in a flutter-free robust configuration. Provisions for incorporation of mechanical damping devices were introduced in the redesigned seal to ensure added robustness

El-Aini, Yehia↗
NASA NTRS1988

Evaluation of coated columbium test panels having application to a secondary nozzle extension for the RL10 rocket engine system, parts 1 and 2

The activity performed on the screening and evaluation of various coatings for application on columbium alloy test panels representative of a radiation-cooled nozzle extension for the RL10 rocket engine is summarized. Vendors and processes of candidate coatings were evaluated. Post engine test evaluations of the two selected coatings are discussed.

Murphy, Kenneth S.↗
NASA NTRS2002

Rocket-Based Combined Cycle Flowpath Testing for Modes 1 and 4

Under sponsorship of the NASA Glenn Research Center (NASA GRC), the Johns Hopkins University Applied Physics Laboratory (JHU/APL) designed and built a five-inch diameter, Rocket-Based Combined Cycle (RBCC) engine to investigate mode 1 and mode 4 engine performance as well as Mach 4 inlet performance. This engine was designed so that engine area and length ratios were similar to the NASA GRC GTX engine is shown. Unlike the GTX semi-circular engine design, the APL engine is completely axisymmetric. For this design, a traditional rocket thruster was installed inside of the scramjet flowpath, along the engine centerline. A three part test series was conducted to determine Mode I and Mode 4 engine performance. In part one, testing of the rocket thruster alone was accomplished and its performance determined (average Isp efficiency = 90%). In part two, Mode 1 (air-augmented rocket) testing was conducted at a nominal chamber pressure-to-ambient pressure ratio of 100 with the engine inlet fully open. Results showed that there was neither a thrust increment nor decrement over rocket-only thrust during Mode 1 operation. In part three, Mode 4 testing was conducted with chamber pressure-to-ambient pressure ratios lower than desired (80 instead of 600) with the inlet fully closed. Results for this testing showed a performance decrease of 20% as compared to the rocket-only testing. It is felt that these results are directly related to the low pressure ratio tested and not the engine design. During this program, Mach 4 inlet testing was also conducted. For these tests, a moveable centerbody was tested to determine the maximum contraction ratio for the engine design. The experimental results agreed with CFD results conducted by NASA GRC, showing a maximum geometric contraction ratio of approximately 10.5. This report details the hardware design, test setup, experimental results and data analysis associated with the aforementioned tests.

Rice, Tharen↗
NASA NTRS1992

Numerical analyses of a rocket engine turbine and comparison with air test data

The study presents cold air test data on the Space Shuttle Main Engine High Pressure Fuel Turbopump turbine recently collected at the NASA Marshall Space Flight Center. Overall performance data, static pressures on the first- and second-stage nozzles, and static pressures along with the gas path at the hub and tip are gathered and compared with various (1D, quasi-3D, and 3D viscous) analysis procedures. The results of each level of analysis are compared to test data to demonstrate the range of applicability for each step in the design process of a turbine. One-dimensional performance prediction, quasi-3D loading prediction, 3D wall pressure distribution prediction, and 3D viscous wall pressure distribution prediction are illustrated.

Tran, Ken↗
NASA NTRS1990

Determination of the durability of the fiberoptics in rocket engine environments

The results of a testing program in which selected optical fibers were exposed to extreme environments representative of those experienced on rocket engines are discussed. Included in the experiment are cold-bend testing, a moisture embrittlement test, a thermal cycling test, temperature extremes testing, vibration testing, and shock testing. Two of the fibers selected, the titanium-carbide-coated and the aluminum-jacketed silica samples succeeded in passing all the tests without a failure.

Delcher, R.↗
NASA NTRS2005

Uncertainty Evaluation of Computational Model Used to Support the Integrated Powerhead Demonstration Project

NASA and the U.S. Air Force are working on a joint project to develop a new hydrogen-fueled, full-flow, staged combustion rocket engine. The initial testing and modeling work for the Integrated Powerhead Demonstrator (IPD) project is being performed by NASA Marshall and Stennis Space Centers. A key factor in the testing of this engine is the ability to predict and measure the transient fluid flow during engine start and shutdown phases of operation. A model built by NASA Marshall in the ROCket Engine Transient Simulation (ROCETS) program is used to predict transient engine fluid flows. The model is initially calibrated to data from previous tests on the Stennis E1 test stand. The model is then used to predict the next run. Data from this run can then be used to recalibrate the model providing a tool to guide the test program in incremental steps to reduce the risk to the prototype engine. In this paper, they define this type of model as a calibrated model. This paper proposes a method to estimate the uncertainty of a model calibrated to a set of experimental test data. The method is similar to that used in the calibration of experiment instrumentation. For the IPD example used in this paper, the model uncertainty is determined for both LOX and LH flow rates using previous data. The successful use of this model is then demonstrated to predict another similar test run within the uncertainty bounds. The paper summarizes the uncertainty methodology when a model is continually recalibrated with new test data. The methodology is general and can be applied to other calibrated models.

Steele, W. G.↗
NASA NTRS2011

Dynamic Loads Generation for Multi-Point Vibration Excitation Problems

A random-force method has been developed to predict dynamic loads produced by rocket-engine random vibrations for new rocket-engine designs. The method develops random forces at multiple excitation points based on random vibration environments scaled from accelerometer data obtained during hot-fire tests of existing rocket engines. This random-force method applies random forces to the model and creates expected dynamic response in a manner that simulates the way the operating engine applies self-generated random vibration forces (random pressure acting on an area) with the resulting responses that we measure with accelerometers. This innovation includes the methodology (implementation sequence), the computer code, two methods to generate the random-force vibration spectra, and two methods to reduce some of the inherent conservatism in the dynamic loads. This methodology would be implemented to generate the random-force spectra at excitation nodes without requiring the use of artificial boundary conditions in a finite element model. More accurate random dynamic loads than those predicted by current industry methods can then be generated using the random force spectra. The scaling method used to develop the initial power spectral density (PSD) environments for deriving the random forces for the rocket engine case is based on the Barrett Criteria developed at Marshall Space Flight Center in 1963. This invention approach can be applied in the aerospace, automotive, and other industries to obtain reliable dynamic loads and responses from a finite element model for any structure subject to multipoint random vibration excitations.

Shen, Lawrence↗
NASA NTRS1993

Spacecraft propulsion systems test capability at the NASA White Sands Test Facility

The NASA White Sands Facility (WSTF), a component insallation of the Johnson Space Center, is located on a 94-square-mile site in southwestern New Mexico. WSTF maintains many unique capabilities to support its mission to test and evaluate spacecraft materials, components, and propulsion systems to enable the safe human exploration and utilization of space. WSTF has tested over 340 rocket engines with more than 2.5 million firings to date. Included are propulsion system testing for Apollo, Shuttle, and now Space Station as well as unmanned spacecraft such as Viking, Pioneer, and Mars Observer. This paper describes the current WSTF propulsion test facilities and capabilities.

Baker, Pleddie↗
NASA NTRS2005

Large Liquid Rocket Testing: Strategies and Challenges

Rocket propulsion development is enabled by rigorous ground testing in order to mitigate the propulsion systems risks that are inherent in space flight. This is true for virtually all propulsive devices of a space vehicle including liquid and solid rocket propulsion, chemical and non-chemical propulsion, boost stage and in-space propulsion and so forth. In particular, large liquid rocket propulsion development and testing over the past five decades of human and robotic space flight has involved a combination of component-level testing and engine-level testing to first demonstrate that the propulsion devices were designed to meet the specified requirements for the Earth to Orbit launchers that they powered. This was followed by a vigorous test campaign to demonstrate the designed propulsion articles over the required operational envelope, and over robust margins, such that a sufficiently reliable propulsion system is delivered prior to first flight. It is possible that hundreds of tests, and on the order of a hundred thousand test seconds, are needed to achieve a high-reliability, flight-ready, liquid rocket engine system. This paper overviews aspects of earlier and recent experience of liquid rocket propulsion testing at NASA Stennis Space Center, where full scale flight engines and flight stages, as well as a significant amount of development testing has taken place in the past decade. The liquid rocket testing experience discussed includes testing of engine components (gas generators, preburners, thrust chambers, pumps, powerheads), as well as engine systems and complete stages. The number of tests, accumulated test seconds, and years of test stand occupancy needed to meet varying test objectives, will be selectively discussed and compared for the wide variety of ground test work that has been conducted at Stennis for subscale and full scale liquid rocket devices. Since rocket propulsion is a crucial long-lead element of any space system acquisition or development, the appropriate plan and strategy must be put in place at the outset of the development effort. A deferment of this test planning, or inattention to strategy, will compromise the ability of the development program to achieve its systems reliability requirements and/or its development milestones. It is important for the government leadership and support team, as well as the vehicle and propulsion development team, to give early consideration to this aspect of space propulsion and space transportation work.

Rahman, Shamim A.↗
NASA NTRS1992

Cold flow testing of the Space Shuttle Main Engine alternate turbopump development high pressure fuel turbine model

NASA's Marshall Space Flight Center has established a cold airflow turbine test program to experimentally determine the performance of liquid rocket engine turbopump drive turbines. Testing of the SSME alternate turbopump development (ATD) fuel turbine was conducted for back-to-back comparisons with the baseline SSME fuel turbine results obtained in the first quarter of 1991. Turbine performance, Reynolds number effects, and turbine diagnostics, such as stage reactions and exit swirl angles, were investigated at the turbine design point and at off-design conditions. The test data showed that the ATD fuel turbine test article was approximately 1.4 percent higher in efficiency and flowed 5.3 percent more than the baseline fuel turbine test article. This paper describes the method and results used to validate the ATD fuel turbine aerodynamic design. The results are being used to determine the ATD high pressure fuel turbopump (HPFTP) turbine performance over its operating range, anchor the SSME ATD steady-state performance model, and validate various prediction and design analyses.

Gaddis, Stephen W.↗
NASA NTRS1989

Thermal modelling of various thermal barrier coatings in a high heat flux rocket engine

Traditional Air Plasma Sprayed (APS) ZrO2-Y2O3 Thermal Barrier Coatings (TBC's) and Low Pressure Plasma Sprayed (LPPS) ZrO2-Y2O3/Ni-Cr-Al-Y cermet coatings were tested in a H2/O2 rocked engine. The traditional ZrO2-Y2O3 (TBC's) showed considerable metal temperature reductions during testing in the hydrogen-rich environment. A thermal model was developed to predict the thermal response of the tubes with the various coatings. Good agreement was observed between predicted temperatures and measured temperatures at the inner wall of the tube and in the metal near the coating/metal interface. The thermal model was also used to examine the effect of the differences in the reported values of the thermal conductivity of plasma sprayed ZrO2-Y2O3 ceramic coatings, the effect of 100 micron (0.004 in.) thick metallic bond coat, the effect of tangential heat transfer around the tube, and the effect or radiation from the surface of the ceramic coating. It was shown that for the short duration testing in the rocket engine, the most important of these considerations was the effect of the uncertainty in the thermal conductivity of temperatures (greater than 100 C) predicted in the tube. The thermal model was also used to predict the thermal response of the coated rod in order to quantify the difference in the metal temperatures between the two substrate geometries and to explain the previously-observed increased life of coatings on rods over that on tubes. A thermal model was also developed to predict heat transfer to the leading edge of High Pressure Fuel Turbopump (HPFTP) blades during start-up of the space shuttle main engines. The ability of various TBC's to reduce metal temperatures during the two thermal excursions occurring on start-up was predicted. Temperature reductions of 150 to 470 C were predicted for 165 micron (0.0065 in.) coatings for the greater of the two thermal excursions.

Nesbitt, James A.↗
NASA NTRS1973

A cooled-gas pyrometer for use in hypersonic engine testing

A cooled-gas pyrometer designed for application in a hypersonic research engine program was fabricated and tested. Design and operational considerations and calibration data are presented. The probe was tested in a rocket-engine exhaust stream operating at Mach 2 and 2300 K. Test temperature measurements agreed to within 2 percent with a radiation shielded thermocouple probe.

Glawe, G. E.↗
NASA NTRS1984

High-pressure hydrogen testing of single crystal superalloys for advanced rocket engine turbopump turbine blades

A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.

Alter, W. S.↗
NASA NTRS1985

High-pressure hydrogen testing of single crystal superalloys for advanced rocket engine turbopump turbine blades

A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.

Parr, R. A.↗
NASA NTRS1990

Orbital transfer vehicle oxygen turbopump technology. Volume 2: Nitrogen and ambient oxygen testing

The testing of a rocket engine oxygen turbopump using high pressure ambient temperature nitrogen and oxygen as the turbine drive gas in separate test series is discussed. The pumped fluid was liquid nitrogen or liquid oxygen. The turbopump (TPA) is designed to operate with 400 F oxygen turbine drive gas which will be demonstrated in a subsequent test series. Following bearing tests, the TPA was finish machined (impeller blading and inlet/outlet ports). Testing started on 15 February 1989 and was successfully concluded on 21 March 1989. Testing started using nitrogen to reduce the ignition hazard during initial TPA checkout. The Hydrostatic Bearing System requires a Bearing Pressurization System. Initial testing used a separate bearing supply to prevent a rubbing start. Two test series were successfully completed with the bearing assist supplied only by the pump second stage output which entailed a rubbing start until pump pressure builds up. The final test series used ambient oxygen drive and no external bearing assist. Total operating time was 2268 seconds. There were 14 starts without bearing assist and operating speeds up to 80,000 rpm were logged. Teardown examination showed some smearing of silverplated bearing surfaces but no exposure of the underlying monel material. There was no evidence of melting or oxidation due to the oxygen exposure. The articulating, self-centering hydrostatic bearing exhibited no bearing load or stability problems. The only anomaly was higher than predicted flow losses which were attributed to a faulty ring seal. The TPA will be refurbished prior to the 400 F oxygen test series but its condition is acceptable, as is, for continued operating. This was a highly successful test program.

Brannam, R. J.↗
NASA NTRS1990

Thermal response of various thermal barrier coatings in a high heat flux rocket engine

Traditional APS ZrO2-Y2O3 thermal barrier coatings (TBCs) formed by air plasma spraying and low pressure and air plasma sprayed ZrO2-Y2O3/NiCrAlY cermet coatings were tested in an H2-O2 rocket engine. The test cycle was approximately 1.2 s at 1400 C in a hydrogen-rich environment. During testing, the maximum metal temperature without a coating was 1310 C. The traditional ZrO2-Y2O3 TBCs with a 100-125 micron thick ceramic layer reduced the maximum metal temperature by approximately 350 C. Increasing the ceramic layer thickness to 200-225 microns resulted in an additional metal temperature reduction of 100 C. However, the cermet coatings, consisting of a ceramic and metal mixture, exhibited a much lower thermal protection capability by reducing the maximum metal temperature by approximately 100 C. It was also found that the surface roughness of the traditional TBCs had little effect on the thermal response.

Nesbitt, J. A.↗