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NASA NTRS2001

Lightweight Chambers for Thrust Assemblies

The Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) has successfully applied new materials and fabrication techniques to create actively cooled thrust chambers that operate 200-400 degrees hotter and weigh 50% lighter than conventional designs. In some vehicles, thrust assemblies account for as much as 20% of the engine weight. So, reducing the weight of these components and increasing their operating range will benefit many engines and vehicle designs, including Reusable Launch Vehicle (RLV) concepts. Obviously, copper and steel alloys have been used successfully for many years in the chamber components of thrust assemblies. Yet, by replacing the steel alloys with Polymer Matrix Composite (PMC) and/or Metal Matrix Composite (MMC) materials, design weights can be drastically reduced. In addition, replacing the traditional copper alloys with a Ceramic Matrix Composite (CMC) or an advanced copper alloy (Cu-8Cr-4Nb, also known as GRCop-84) significantly increases allowable operating temperatures. Several small MMC and PMC demonstration chambers have recently been fabricated with promising results. Each of these designs included GRCop-84 for the cooled chamber liner. These units successfully verified that designs over 50% lighter are feasible. New fabrication processes, including advanced casting technology and a low cost vacuum plasma spray (VPS) process, were also demonstrated with these units. Hot-fire testing at MSFC is currently being conducted on the chambers to verify increased operating temperatures available with the GRCop-84 liner. Unique CMC chamber liners were also successfully fabricated and prepared for hot-fire testing. Yet, early results indicate these CMC liners need significantly more development in order to use them in required chamber designs. Based on the successful efforts with the MMC and PMC concepts, two full size "lightweight" chambers are currently being designed and fabricated for hot-fire testing at MSFC in 2001. These "full size" chambers will be similar in size to those used on the X33 engine (RS2200). One will be fabricated with a MMC structural jacket, while the other uses a PMC jacket. Each will be designed for thrust levels of 15,000 pounds in an oxygen/hydrogen environment with liquid hydrogen coolant. Both chambers will use GRCop-84 for its channel wall liner. Each unit is expected to be at least 60% lighter than a conventional design with traditional materials. Hot-fire testing on the full size units in late 2001 will directly compare performance results between a conventional chamber design and these "lightweight" alternatives. The technology developed and demonstrated by this effort will not only benefit next generation RLV programs, but it can be applied to other existing and future engine programs, as well. Efforts were sponsored by the Advanced Space Transportation Program for RLV Focused Technologies. The task team was led by MSFC with additional members from NASA-Glenn Research Center and the Rocketdyne Division of The Boeing Company. Specific materials development and fabrication processes were provided by Aerojet, Lockheed Martin Astronautics, Composite Optics, Inc., Hyper-Therm, Ceramic Composites, Inc., MSE Technology Applications, and Plasma Processes, Inc.

Elam, Sandra K.↗
NASA NTRS2001

Evaluation of CFD Turbulent Heating Prediction Techniques and Comparison With Hypersonic Experimental Data

Results from a study to assess the accuracy of turbulent heating and skin friction prediction techniques for hypersonic applications are presented. The study uses the original and a modified Baldwin-Lomax turbulence model with a space marching code. Grid converged turbulent predictions using the wall damping formulation (original model) and local damping formulation (modified model) are compared with experimental data for several flat plates. The wall damping and local damping results are similar for hot wall conditions, but differ significantly for cold walls, i.e., T(sub w) / T(sub t) < 0.3, with the wall damping heating and skin friction 10-30% above the local damping results. Furthermore, the local damping predictions have reasonable or good agreement with the experimental heating data for all cases. The impact of the two formulations on the van Driest damping function and the turbulent eddy viscosity distribution for a cold wall case indicate the importance of including temperature gradient effects. Grid requirements for accurate turbulent heating predictions are also studied. These results indicate that a cell Reynolds number of 1 is required for grid converged heating predictions, but coarser grids with a y(sup +) less than 2 are adequate for design of hypersonic vehicles. Based on the results of this study, it is recommended that the local damping formulation be used with the Baldwin-Lomax and Cebeci-Smith turbulence models in design and analysis of Hyper-X and future hypersonic vehicles.

Dilley, Arthur D.↗
NASA NTRS2000

JANNAF 25Th Airbreathing Propulsion Subcommittee, 37Th Combustion Subcommittee and 1St Modeling and Simulation Subcommittee Joint Meeting

Contents include the following: 1. Hyper-X program: Propulsion development and verification. 2. GTX program: Airbreathing launch vehicles. 3. Hypersonic technology development: Technology program overviews. Ramjet/scramjet research. 4. Hypersonic test methods: Test medium effects. 5. Advanced propulsion: RBCC engine design and performance assessments. Advanced and combined cycle engine technology.

Fry, Ronald S.↗
NASA NTRS2000

JANNAF 25th Airbreathing Propulsion Subcommittee, 37th Combustion Subcommittee and 1st Modeling and Simulation Subcommittee Joint Meeting

Volume I, the first of three volumes, is a compilation of 24 unclassified/unlimited-distribution technical papers presented at the Joint Army-Navy-NASA-Air Force (JANNAF) 25th Airbreathing Propulsion Subcommittee, 37th Combustion Subcommittee and 1st Modeling and Simulation Subcommittee (MSS) meeting held jointly with the 19th Propulsion Systems Hazards Subcommittee. The meeting was held 13-17 November 2000 at the Naval Postgraduate School and Hyatt Regency Hotel, Monterey, California. Topics covered include: a Keynote Address on Future Combat Systems, a review of the new JANNAF Modeling and Simulation Subcommittee, and technical papers on Hyper-X propulsion development and verification; GTX airbreathing launch vehicles; Hypersonic technology development, including program overviews, fuels for advanced propulsion, ramjet and scramjet research, hypersonic test medium effects; and RBCC engine design and performance, and PDE and UCAV advanced and combined cycle engine technologies.

Fry, Ronald S.↗
NASA NTRS1994

Development of a Feeder for Uninterrupted Centrifugation Studies

A specialized paste diet feeder was developed in support of a hypergravity (2G) centrifuge study. The centrifuge study was to be compared to a previously flown Russian Cosmos spaceflight so experimental parameters of the 14 day spaceflight had to be duplicated. In order to duplicate at hyper G an experiment that took place in weightlessness, all other conditions must be as identical as possible. Stopping the centrifuge to provide maintenance for the animals causes unacceptable changes in experimental research results. Thus the experimental protocol required the delivery of a designated amount of paste diet at regular intervals for a two week period without stopping the centrifuge. A centrifuge and a stationary control cage, each containing 10 laboratory rats, were fitted with feeders that were calibrated to provide 140 plus or minus 2g of paste diet every 6 hours. This paper describes development of the feeder design and results of its operation over the two week experiment. The design philosophy and details of the feeder system are provided with recommendations for future such devices.

Mulenburg, Gerald M.↗
NASA NTRS2001

Alleviation of Facility/Engine Interactions in an Open-Jet Scramjet Test Facility

Results of a series of shakedown tests to eliminate facility/engine interactions in an open-jet scramjet test facility are presented. The tests were conducted with the NASA DFX (Dual-Fuel eXperimental scramjet) engine in the NASA Langley Combustion Heated Scramjet Test Facility (CHSTF) in support of the Hyper-X program, The majority of the tests were conducted at a total enthalpy and pressure corresponding to Mach 5 flight at a dynamic pressure of 734 psf. The DFX is the largest engine ever tested in the CHSTF. Blockage, in terms of the projected engine area relative to the nozzle exit area, is 81% with the engine forebody leading edge aligned with the upper edge of the facility nozzle such that it ingests the nozzle boundary layer. The blockage increases to 95% with the engine forebody leading edge positioned 2 in. down in the core flow. Previous engines successfully tested in the CHSTF have had blockages of no more than 51%. Oil flow studies along with facility and engine pressure measurements were used to define flow behavior. These results guided modifications to existing aeroappliances and the design of new aeroappliances. These changes allowed fueled tests to be conducted without facility interaction effects in the data with the engine forebody leading edge positioned to ingest the facility nozzle boundary layer. Interaction effects were also reduced for tests with the engine forebody leading edge positioned 2 in. into the core flow, however some interaction effects were still evident in the engine data. A new shroud and diffuser have been designed with the goal of allowing fueled tests to be conducted with the engine forebody leading edge positioned in the core without facility interaction effects in the data. Evaluation tests of the new shroud and diffuser will be conducted once ongoing fueled engine tests have been completed.

Albertson, Cindy W.↗
NASA NTRS2001

Scramjet Tests in a Shock Tunnel at Flight Mach 7, 10, and 15 Conditions

Tests of the Hyper-X scramjet engine flowpath have been conducted in the HYPULSE shock tunnel at conditions duplicating the stagnation enthalpy at flight Mach 7, 10, and 15. For the tests at Mach 7 and 10 HYPULSE was operated as a reflected-shock tunnel; at the Mach 15 condition, HYPULSE was operated as a shock-expansion tunnel. The test conditions matched the stagnation enthalpy of a scramjet engine on an aerospace vehicle accelerating through the atmosphere along a 1000 psf dynamic pressure trajectory. Test parameter variation included fuel equivalence ratios from lean (0.8) to rich (1.5+); fuel composition from pure hydrogen to mixtures of 2% and 5% silane in hydrogen by volume; and inflow pressure and Mach number made by changing the scramjet model mounting angle in the HYPULSE test chamber. Data sources were wall pressures and heat flux distributions and schlieren and fuel plume imaging in the combustor/nozzle sections. Data are presented for calibration of the facility nozzles and the scramjet engine model. Comparisons of pressure distributions and flowpath streamtube performance estimates are made for the three Mach numbers tested.

Rogers, R. C.↗
NASA NTRS2001

Numerical Simulation of One- and Two-Phase Flows in Propulsion Systems

In this report, we present some results of problems investigated during joint research between the Hampton University Fluid Mechanics and Acoustics Laboratory (HU/FM&AL), NASA GRC, and the LaRC Hyper-X Program. This work is supported by joint research between the NASA GRC and the Institute of Mechanics at Moscow State University (IM/MSU) in Russia under a CRDF grant. The main areas of current scientific interest of the HU/FM&AL include an investigation of the proposed and patented advanced methods for aircraft engine thrust and noise benefits. These methods are based on nontraditional 3D corrugated and composite nozzle, inlet, propeller and screw designs such as a Bluebell and Telescope nozzle, Mobius-shaped screw, etc. This is the main subject of our other projects, of which one is presented at the current conference. Here we analyze additional methods for exhaust jet noise reduction without essential thrust loss and even with thrust augmentation. Such additional approaches are: (1) to add some solid, fluid, or gas mass at discrete locations to the main supersonic gas stream to minimize the negative influence of strong shock waves formed in propulsion systems. This mass addition may be accompanied by heat addition to the main stream as a result of the fuel combustion or by cooling of this stream as a result of the liquid mass evaporation and boiling; (2) Use of porous or permeable nozzles and additional shells at the nozzle exit for preliminary cooling of the hot jet exhaust and pressure compensation for off-design conditions (so-called continuous ejector with small mass flow rate); and (3) to propose and analyze new effective methods of fuel injection into the flow stream in air-breathing engines. The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines. The FM&AL Team uses analytical methods, numerical simulations, and experimental tests at the Hampton University campus, NASA, and IM/MSU. The main outcomes during this reporting period are: (1) Publications: The AIAA Paper #01-1893 has been accepted for the AIAA/NAL-NASDA-ISAS 10th International Space Planes and Hypersonic Systems and Technologies Conference, 24-27 April 2001, Kyoto, Japan. The AIAA Paper #01-3204 has been accepted for presentation at the 37th AIAA/ASME/SAE/ASEE Joint Propulsion Conference being held on 08-11 July, in Salt Lake City, UT; (2) Grants and proposals: The HU/FM&AL was awarded the NASA grant NAG3-2495 in October 2000 and the CRDF award was granted to the NASA GRC-HU FM&AL and IM/MSU (Russia) in July 2000. A solicited proposal was submitted for the NASA NRA-01GRC-02 competition and two unsolicited proposals to NASA are in preparation; (3) Theory and numerical simulations: Analytical theory, numerical simulation, comparison of theoretical with experimental results, and modification of theoretical approaches, models, grids, etc. Such investigations have been conducted for three main problems: (a) Combustion efficiency optimization in the half-duct combustor system; (b) Drag reduction effects for blunt bodies with solid needles; and (c) Solid particle injection from the butt-end against a supersonic flow. The NASA CFL3D, HU/FM&AL, and IM/MSU GODUNOV codes were used and modified for solution of these problems. The codes are based on full Euler and Navier-Stokes solvers with and without nonequilibrium oxygen-nitrogen and air-hydrogen chemical reactions in laminar and turbulent gas flow regimes; (4) Experimental tests: In the IM/MSU supersonic wind tunnel, experimental tests were conducted with different number, location, and geometric parameters of solid needles mounted at the front of the butt-end in supersonic flow. Optimal parameters were determined that provide minimal butt-end drag in the stationary flow regime. Experimental and numerical simulation results are in good agreement; (5) Student Research Activity: Involvement of one graduate and two undergraduate students as research assistants in the current project.

Gilinsky, Mikhail↗
NASA NTRS2001

Interpretation of Observations of Trans-Spectral Phenomena Acquired Using Hyperspectral Sensors Aboard a Remotely Operated Vehicle in Exuma Sound

Hyper-spectral (512-channel) optical data acquired during a relatively deep (102m) dive of our ROSEBUD Remotely Operated Vehicle (ROV) in the clear waters of Exuma Sound, Bahamas provided the opportunity to investigate the trans-spectral shift of photonic energy (inelastic scattering) as a function of water depth. Results show a convolution of several spectral processes (e.g. absorption, scattering) involving water molecules, dissolved material and particulates as well as trans-spectral (inelastic) processes involving fluorescence by water molecules (Raman), dissolved material and chlorophyll. The spectral signatures of these convolved causes and effects allow deconvolution with a hyperspectral approach. Intrinsic to the convolution was the ability to position the vehicle at depths where Raman fluorescence dominated at red wavelengths. Results show that the calculated Raman absorption coefficients are generally consistent with historical values (i.e. 0.9 x 10(sup)-4 at 525 nm excitation) and that an angstrom exponent of 5 is more appropriate than the often cited value of 4.

Costello, D.↗
NASA NTRS2002

Numerical Simulation of One- And Two-Phase Flows In Propulsion Systems

In this report, we present some results of problems investigated during joint research between the Hampton University (HU) Fluid Mechanics and Acoustics Laboratory (FM&AL), NASA Glenn Research Center (GRC) and the Hyper-X Program of the NASA Langley Research Center (LaRC). This work is supported by joint research between the NASA GRC/HU FM&AL and the Institute of Mechanics at Moscow State University (IM/MSU) in Russia under a Civilian Research and Development Foundation (CRDF) grant, #RE1-2068. The main areas of current scientific interest of the FM&AL include an investigation of the proposed and patented advanced methods for aircraft engine thrust and noise benefits. These methods are based on nontraditional 3D (three dimensional) corrugated and composite nozzle, inlet, propeller and screw designs such as the Bluebell and Telescope nozzles, Mobius-shaped screws, etc. These are the main subject of our other projects, of which one is the NASA MURED's (Minority University Research and Education Division) FAR (Faculty Awards for Research) Award, #NAG-3-2249. Working jointly with this project team, our team also analyzes additional methods for exhaust jet noise reduction. These methods are without essential thrust loss and even with thrust augmentation. The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines. The FM&AL Team uses analytical methods, numerical simulations and experimental tests at the Hampton University campus, NASA and IM/MSU. The main results obtained by FM&AL team were published in the papers and patents.

Gilinsky, Mikhail M.↗
NASA NTRS2001

Parallelization of the Flow Field Dependent Variation Scheme for Solving the Triple Shock/Boundary Layer Interaction Problem

A parallelized version of the Flowfield Dependent Variation (FDV) Method is developed to analyze a problem of current research interest, the flowfield resulting from a triple shock/boundary layer interaction. Such flowfields are often encountered in the inlets of high speed air-breathing vehicles including the NASA Hyper-X research vehicle. In order to resolve the complex shock structure and to provide adequate resolution for boundary layer computations of the convective heat transfer from surfaces inside the inlet, models containing over 500,000 nodes are needed. Efficient parallelization of the computation is essential to achieving results in a timely manner. Results from a parallelization scheme, based upon multi-threading, as implemented on multiple processor supercomputers and workstations is presented.

Schunk, Richard Gregory↗
NASA NTRS2001

Improved Quick Disconnect (QD) Interface Through Fail Safe Parts Identification

An extensive review of existing Quick Disconnects (QDs) mating and demating operations was performed to determine which shuttle part interface identifications and procedures contribute to human factor errors. The research methods used consisted of interviews with engineers and technicians, examination of incident reports, critiques of video and audio tapes of QD operations, and attendance of a Hyper QD operational course. The data strongly suggests that there are inherit human factor errors involved in QD operations. To promote fail-safe operations, QD interface problem areas and recommendations were outlined and reviewed. It is suggested that dialogue, investigations and recommendations continue.

Blanch-Payne, Evelyn↗
NASA NTRS2002

Database Reports Over the Internet

Most of the summer was spent developing software that would permit existing test report forms to be printed over the web on a printer that is supported by Adobe Acrobat Reader. The data is stored in a DBMS (Data Base Management System). The client asks for the information from the database using an HTML (Hyper Text Markup Language) form in a web browser. JavaScript is used with the forms to assist the user and verify the integrity of the entered data. Queries to a database are made in SQL (Sequential Query Language), a widely supported standard for making queries to databases. Java servlets, programs written in the Java programming language running under the control of network server software, interrogate the database and complete a PDF form template kept in a file. The completed report is sent to the browser requesting the report. Some errors are sent to the browser in an HTML web page, others are reported to the server. Access to the databases was restricted since the data are being transported to new DBMS software that will run on new hardware. However, the SQL queries were made to Microsoft Access, a DBMS that is available on most PCs (Personal Computers). Access does support the SQL commands that were used, and a database was created with Access that contained typical data for the report forms.

Dean Lance Smith↗
NASA NTRS2002

A Large Sparse Aperture Densified Pupil Hypertelescope Concept for Ground Based Detection of Extra-Solar Earth-Like Planets

A concept is presented for a large (10 - 30 meter) sparse aperture hyper telescope to image extrasolar earth-like planets from the ground in the presence of atmospheric seeing. The telescope achieves high dynamic range very close to bright stellar sources with good image quality using pupil densification techniques. Active correction of the perturbed wavefront is simplified by using 36 small flat mirrors arranged in a parabolic steerable array structure, eliminating the need for large delat lines and operating at near-infrared (1 - 3 Micron) wavelengths with flats comparable in size to the seeing cells.

Gezari, D.↗
NASA NTRS2002

The Aircraft Simulation Role in Improving Flight Safety Through Control Room Training

NASA Dryden Flight Research Center uses its six-degrees-of-freedom (6-DOF) fixed-base simulations for mission control room training to improve flight safety and operations. This concept is applied to numerous flight projects such as the F-18 High Alpha Research Vehicle (HARV), the F-15 Intelligent Flight Control System (IFCS), the X-38 Actuator Control Test (XACT), and X-43A (Hyper-X). The Dryden 6-DOF simulations are typically used through various stages of a project, from design to ground tests. The roles of these simulations have expanded to support control room training, reinforcing flight safety by building control room staff proficiency. Real-time telemetry, radar, and video data are generated from flight vehicle simulation models. These data are used to drive the control room displays. Nominal static values are used to complete information where appropriate. Audio communication is also an integral part of training sessions. This simulation capability is used to train control room personnel and flight crew for nominal missions and emergency situations. Such training sessions are also opportunities to refine flight cards and control room display pages, exercise emergency procedures, and practice control room setup for the day of flight. This paper describes this technology as it is used in the X-43A and F-15 IFCS and XACT projects.

Shy, Karla S.↗
NASA NTRS2002

Tethers as Debris: Hydrocode Simulation of Impacts of Tether Fragments on Planar Aerospace Materials

Tethers promise to find use in a variety of space applications. Despite being narrow objects, their great lengths result in them having large total areas, and so tethers are quite susceptible to being severed by orbital debris. Extensive work has been done designing tethers that resist severs by small debris objects, and hence have longer working lives. It is from this perspective that most recent work has considered the tether - debris question. The potential of intact tethers, or severed tether fragments, as debris to pose a significant collision risk to other spacecraft has been less well studied. Understanding the consequences of such encounters is important in assessing the risks to other spacecraft posed by tethers. In this paper I discuss the damage that two types of tethers may produce on planar aerospace materials, as revealed by hyper- velocity impact simulations using the SPHC hydrodynamic code. Tether types considered include a single nylon line and a complex design including metal wires. Target materials considered include the aluminum plates typically used in debris shielding, and solar panels.

Evans, Steven W.↗
NASA NTRS2003

Lessons Learned From Developing A Streaming Data Framework for Scientific Analysis

We describe the development and usage of a streaming data analysis software framework. The framework is used for three different applications: Earth science hyper-spectral imaging analysis, Electromyograph pattern detection, and Electroencephalogram state determination. In each application the framework was used to answer a series of science questions which evolved with each subsequent answer. This evolution is summarized in the form of lessons learned.

Wheeler. Kevin R.↗
NASA NTRS2003

Evaluation of Genetic Algorithm Concepts using Model Problems: Single-Objective Optimization - Part 1

A genetic-algorithm-based optimization approach is described and evaluated using a simple hill-climbing model problem. The model problem utilized herein allows for the broad specification of a large number of search spaces including spaces with an arbitrary number of genes or decision variables and an arbitrary number hills or modes. In the present study, only single objective problems are considered. Results indicate that the genetic algorithm optimization approach is flexible in application and extremely reliable, providing optimal results for all problems attempted. The most difficult problems - those with large hyper-volumes and multi-mode search spaces containing a large number of genes - require a large number of function evaluations for GA convergence, but they always converge.

Holst, Terry L.↗