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Elastomeric bearings eliminate extraneous forces. Rocket thrust transmitted from motor to load cells via support that absorbs extraneous forces so they do not affect accuracy of thrust measurements. Adapter spoked cone fits over forward end of rocket motor. Shock mounting developed for rocket engines under test used as support for heavy machines, bridges, or towers.
In order to provide the information necessary to develop a rocket engine ground test failure detection monitor which keys on anomalous activity in the plume, a series of experimental observations were made during single engine Space Shuttle Main Engine (SSME) tests. The observations were conducted from the 220 nm wavelength in the ultraviolet out to the 15 micron wavelength in the infrared. Four types of instruments were employed including analog autoranging narrow band radiometers, optical multichannel analyzers, mechanical scanning and film plate spectrometers, and imaging cameras. Some results included: strong OH radiation in the UV up to vibrational transition state four; Na and K radiation lines in all phases of engine operation; reaction of some of the instruments to minor engine anomalies; good shock structure imaging; striations in the flow in the 310 nm OH band; and detection of gross changes in engine operating state such as start or shutdown.
Experiments were performed on a passive tuned electromagnetic damper that could be used for damping rotor vibrations in cryogenic turbopumps for rocket engines. The tests were performed in a rig that used liquid nitrogen to produce cryogenic turbopump temperatures. This damper is most effective at cryogenic temperatures and is not a viable damper at room temperature. The unbalanced amplitude response of the rotor shaft was measured for undamped (baseline) and damped conditions at the critical speeds of the rotor (approx. 5900 to 6400 rpm) and the data were compared. The tests were performed for a speed range between 900 and 10 000 rpm. The tests revealed that the damper is very effective for damping single-mode narrow bandwidth amplitude response but is less effective in damping broadband response or multimode amplitude response.
In recent years analytical tools to characterize combustor flow have been developed in order to support design. To facilitate anchoring of combustion related physical models and the CFD codes in which they are incorporated, considerable development and application of non-intrusive combustion diagnostic capabilities has occurred. Raman spectroscopy can be used to simultaneously detect all polyatomic molecules present in significant concentrations and to determine gas temperature. This is because all molecules possess a distinct temperature dependent Raman spectrum. A multi-point diagnostic system for non-intrusive temperature and species profiling in rocket engines has been developed at Rocketdyne. In the present effort, the system has been undergoing validation for application to rocket engine component testing. A 4 inch diameter windowed combustor with a coaxial gas-gas injector was chosen for this series of validation experiments. Initially an excimer-pumped tunable dye laser and later a solid state Nd-Yag laser served as excitation sources. The Raman signal was dispersed by a monochromator and detected by a gated, intensified Charged Coupled Device (CCD) array. Experiments were carried out prior to each series of hot fire tests to ensure that the Raman signal detected was due to a spontaneous rather than a stimulated Raman emission process. Over sixty hot fire tests were conducted during the first series of tests with the excimer/dye laser. All hot fire testing was at a mixture ratio of 0.5 and chamber pressures of approximately 100 and approximately 300 psia. The Raman spectra of hydrogen, water vapor and oxygen recorded during single element hot fire tests were reduced and analyzed. A significant achievement was the attainment of single shot Raman spectra in cold flow tests. Unfortunately, the single shot signal-to-noise ratio deteriorated to an unacceptable level during the hot fire testing. Attempts to obtain temperature data from the hydrogen Q1-branch profiles obtained in hot fire tests suggest that potentially complicating factors may render the approach of averaging data on the photodiode array invalid. A second series of hot fire tests was conducted with a 4 element coaxial injector using the Nd-Yag laser. A very compact and portable diagnostics set up was assembled for ease of alignment, relocation and flexibility. Measurements were made at several regions in the chamber in order to map concentration profiles. High spatial resolution and improved signal to noise characteristics were demonstrated.
The initial efforts to develop the capability to model valves used in rocket engine component testing at Stennis Space Center are documented. An axisymmetric model of a control valve with LN2 as the working fluid was developed. The goal was to predict the effect of change in the plug/sear region of the valve prior to testing. The valve flow coefficient was predicted for a range of plug positions. Verification of the calculations was carried out to quantify the uncertainty in the numerical answer. The modeled results compared well qualitatively to experimental trends. Additionally, insights into the flow processes in the valve were obtained. Benefits from the verification process included the ability to use coarser grids and insight into ways to reduce computational time by using double precision accuracy and non-integer grid ratios. Future valve modeling activities will include shape optimization of the valve/seat region and dynamic grid modeling.
In this paper computational modeling efforts undertaken at NASA Stennis Space Center in support of rocket engine component testing are discussed. Such analyses include structurally complex cryogenic liquid valves and gas valves operating at high pressures and flow rates. Basic modeling and initial successes are documented, and other issues that make valve modeling at SSC somewhat unique are also addressed. These include transient behavior, valve stall, and the determination of flow patterns in LOX valves. Hexahedral structured grids are used for valves that can be simplifies through the use of axisymmetric approximation. Hybrid unstructured methodology is used for structurally complex valves that have disparate length scales and complex flow paths that include strong swirl, local recirculation zones/secondary flow effects. Hexahedral (structured), unstructured, and hybrid meshes are compared for accuracy and computational efficiency. Accuracy is determined using verification and validation techniques.
The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests and/or deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four degrees of ovalization of the nozzle: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The computed side load physics caused by the nozzle out-of-roundness and its effect on nozzle side load are reported and discussed.
The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads at a high altitude, with an anchored computational methodology. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests, and deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four different degrees of ovalization: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation-line-jump is the peak side load physics for the round, slightly our-of-round, and more out-of-round cases, and the peak side load increases as the degree of out-of-roundness increases. For the significantly out-of-round nozzle, however, the peak side load reduces to comparable to that of the round nozzle and the separation line jump is not the peak side load physics. The counter-intuitive result of the significantly out-of-round case is found to be related to a side force reduction mechanism that splits the effect of the separation-line-jump into two parts, not only in the circumferential direction and most importantly in time.
On December 17, 1903, Orville Wright piloted the first powered airplane only 20 feet above the ground near Kitty Hawk, North Carolina. The flight lasted 12 seconds and covered 120 feet. Who would have guessed that the bizarre looking contraption developed by brothers in the bicycle business would lay the ground work eventually resulting in over a million passengers moved daily in a sky filled with the contrails of jets flying at over 30,000 feet in elevation and over 500 miles per hour. Similarly, who would have guessed that the destructive nature of V-2 rockets of Germany would spark the genesis of spaceflight to explore our solar system and beyond? Yet the interest in using the Kennedy Space Center (KSC) continues to grow. Potential customers have expressed interest in KSC as a location for testing new rocket engines, servicing the world's largest airborne launching platform for drop-launch rockets, developing multi-use launch platforms that permit diverse customers to use the same launch platform, developing new spacecraft, and implementing advanced modifications for lifting 150 metric ton payloads to low earth orbit. The multitude of customers has grown and with this growth comes a need to provide a command, control, communication, and range infrastructure that maximizes flexibility and reconfigurability to address a much more frequent launch rate of diverse vehicles and spacecraft. The Ground Systems Development and Operations (GSDO) Program Office at KSC is embarking upon these developments to realize the dream of a robust spaceport. Many unique technical trade studies have been completed or are underway to successfully transition KSC into a multi-user customer focused spaceport. Like the evolution of the airplane, GSDO is working to transform KSC infrastructures that will turn once unthinkable space opportunities into a reality for today.
An integrated fiber-optic Raman sensor has been designed for real-time, nonintrusive detection of liquid nitrogen in liquid oxygen (LOX) at high pressures and high flow rates in order to monitor the quality of LOX used during rocket engine ground testing. The integrated sensor employs a high-power (3-W) Melles Griot diode-pumped, solid-state (DPSS), frequency-doubled Nd:YAG 532- nm laser; a modified Raman probe that has built-in Raman signal filter optics; two high-resolution spectrometers; and photomultiplier tubes (PMTs) with selected bandpass filters to collect both N2 and O2 Raman signals. The PMT detection units are interfaced with National Instruments Lab- VIEW for fast data acquisition. Studies of sensor performance with different detection systems (i.e., spectrometer and PMT) were carried out. The concentration ratio of N2 and O2 can be inferred by comparing the intensities of the N2 and O2 Raman signals. The final system was fabricated to measure N2 and O2 gas mixtures as well as mixtures of liquid N2 and LOX
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NASA has recently completed testing of a ceramic matrix composite (CMC), integrally bladed disk (blisk) for rocket engine turbopumps. The turbopump's main function is to bring propellants from the tank to the combustion chamber at optimal pressures, temperatures, and flow rates. Advantages realized by using CMC blisks are increases in safety by increasing temperature margins and decreasing costs by increasing turbopump performance. A multidisciplinary team, involving materials, design, structural analysis, nondestructive inspection government, academia, and industry experts, was formed to accomplish the 4.5 year effort. This article will review some of the background and accomplishments of the CMC Blisk Program relative to the benefits of this technology.
ORBITEC is developing methods for producing, testing, and utilizing Mars-based ISRU fuel/oxidizer combinations to support low cost, planetary surface and flight propulsion and power systems. When humans explore Mars we will need to use in situ resources that are available, such as: energy (solar); gases or liquids for life support, ground transportation, and flight to and from other surface locations and Earth; and materials for shielding and building habitats and infrastructure. Probably the easiest use of Martian resources to reduce the cost of human exploration activities is the use of the carbon and oxygen readily available from the CO2 in the Mars atmosphere. ORBITEC has conducted preliminary R&D that will eventually allow us to reliably use these resources. ORBITEC is focusing on the innovative use of solid CO as a fuel. A new advanced cryogenic hybrid rocket propulsion system is suggested that will offer advantages over LCO/LOX propulsion, making it the best option for a Mars sample return vehicle and other flight vehicles. This technology could also greatly support logistics and base operations by providing a reliable and simple way to store solar or nuclear generated energy in the form of chemical energy that can be used for ground transportation (rovers/land vehicles) and planetary surface power generators. This paper describes the overall concept and the test results of the first ever solid carbon monoxide/oxygen rocket engine firing.
While NASA's current next-generation launch vehicle research has largely focused on advanced all-rocket single-stage-to-orbit vehicles (i.e. the X-33 and it's RLV operational follow-on), some attention is being given to advanced propulsion concepts suitable for 'next-generation-and-a-half' vehicles. Rocket-based combined-cycle (RBCC) engines combining rocket and airbreathing elements are one candidate concept. Preliminary RBCC engine development was undertaken by the United States in the 1960's. However, additional ground and flight research is required to bring the engine to technological maturity. This paper presents two options for flight testing early versions of the RBCC ejector scramjet engine. The first option mounts a single RBCC engine module to the X-34 air-launched technology testbed for test flights up to about Mach 6.4. The second option links RBCC engine testing to the simultaneous development of a small-payload (220 lb.) two-stage-to-orbit operational vehicle in the Bantam payload class. This launcher/testbed concept has been dubbed the W vehicle. The W vehicle can also serve as an early ejector ramjet RBCC launcher (albeit at a lower payload). To complement current RBCC ground testing efforts, both flight test engines will use earth-storable propellants for their RBCC rocket primaries and hydrocarbon fuel for their airbreathing modes. Performance and vehicle sizing results are presented for both options.
Vacuum-ignition phenomena in Apollo rocket engine when oriented in upward-firing attitude
A 40-percent scale model of the inlet to a rocket-based combined-cycle (RBCC) engine was tested in the NASA Glenn Research Center 1- by 1-Foot Supersonic Wind Tunnel (SWT). The full-scale RBCC engine is scheduled for test in the Hypersonic Tunnel Facility (HTF) at NASA Glenn's Plum Brook Station at Mach 5 and 6. This engine will incorporate the configuration of this inlet model which achieved the best performance during the present experiment. The inlet test was conducted at Mach numbers of 4.0, 5.0, 5.5, and 6.0. The fixed-geometry inlet consists of an 8 deg.. forebody compression plate, boundary layer diverter, and two compressive struts located within 2 parallel sidewalls. These struts extend through the inlet, dividing the flowpath into three channels. Test parameters investigated included strut geometry, boundary layer ingestion, and Reynolds number (Re). Inlet axial pressure distributions and cross-sectional Pitot-pressure surveys at the base of the struts were measured at varying back-pressures. Inlet performance and starting data are presented. The inlet chosen for the RBCC engine self-started at all Mach numbers from 4 to 6. Pitot-pressure contours showed large flow nonuniformity on the body-side of the inlet. The inlet provided adequate pressure recovery and flow quality for the RBCC cycle even with the flow separation.