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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.↗

NASA NTRS1996

Validation of High Aspect Ratio Cooling in a 89 kN (20,000 lb(sub f)) Thrust Combustion Chamber

In order to validate the benefits of high aspect ratio cooling channels in a large scale rocket combustion chamber, a high pressure, 89 kN (20,000 lbf) thrust, contoured combustion chamber was tested in the NASA Lewis Research Center Rocket Engine Test Facility. The combustion chamber was tested at chamber pressures from 5.5 to 11.0 MPa (800-1600 psia). The propellants were gaseous hydrogen and liquid oxygen at a nominal mixture ratio of six, and liquid hydrogen was used as the coolant. The combustion chamber was extensively instrumented with 30 backside skin thermocouples, 9 coolant channel rib thermocouples, and 10 coolant channel pressure taps. A total of 29 thermal cycles, each with one second of steady state combustion, were completed on the chamber. For 25 thermal cycles, the coolant mass flow rate was equal to the fuel mass flow rate. During the remaining four thermal cycles, the coolant mass flow rate was progressively reduced by 5, 6, 11, and 20 percent. Computer analysis agreed with coolant channel rib thermocouples within an average of 9 percent and with coolant channel pressure drops within an average of 20 percent. Hot-gas-side wall temperatures of the chamber showed up to 25 percent reduction, in the throat region, over that of a conventionally cooled combustion chamber. Reducing coolant mass flow yielded a reduction of up to 27 percent of the coolant pressure drop from that of a full flow case, while still maintaining up to a 13 percent reduction in a hot-gas-side wall temperature from that of a conventionally cooled combustion chamber.

Wadel, Mary F.↗

NASA NTRS2010

Combustion and Performance Analyses of Coaxial Element Injectors with Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in a flight-qualified engine system, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented activities with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, the NASA Marshall Space Flight Center has conducted combustion, performance, and combustion stability analyses of several of the configurations. This paper summarizes the analyses of combustion and performance as a follow-up to a paper published in the 2008 JANNAF/LPS meeting. Combustion stability analyses are presented in a separate paper. The current paper includes test and analysis results of coaxial element injectors using liquid oxygen and liquid methane or gaseous methane propellants. Several thrust chamber configurations have been modeled, including thrust chambers with multi-element swirl coax element injectors tested at the NASA MSFC, and a uni-element chamber with shear and swirl coax injectors tested at The Pennsylvania State University. Configurations were modeled with two one-dimensional liquid rocket combustion analysis codes, the Rocket Combustor Interaction Design and Analysis (ROCCID), and the Coaxial Injector Combustion Model (CICM). Significant effort was applied to show how these codes can be used to model combustion and performance with oxygen/methane propellants a priori, and what anchoring or calibrating features need to be applied or developed in the future. This paper describes the test hardware configurations, presents the results of all the analyses, and compares the results from the two analytical methods

Hulka, J. R.↗

NASA NTRS2010

Performance and Stability Analyses of Rocket Combustion Devices Using Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in flight-qualified engine systems, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented programs with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, NASA Marshall Space Flight Center has conducted combustion, performance, and combustion stability analyses of several of the configurations on these programs. This paper summarizes these analyses. Test and analysis results of impinging and coaxial element injectors using liquid oxygen and liquid methane propellants are included. Several cases with gaseous methane are included for reference. Several different thrust chamber configurations have been modeled, including thrust chambers with multi-element like-on-like and swirl coax element injectors tested at NASA MSFC, and a unielement chamber with shear and swirl coax injectors tested at The Pennsylvania State University. Configurations were modeled with two one-dimensional liquid rocket combustion analysis codes, the Rocket Combustor Interaction Design and Analysis (ROCCID), and the Coaxial Injector Combustion Model (CICM). Significant effort was applied to show how these codes can be used to model combustion and performance with oxygen/methane propellants a priori, and what anchoring or calibrating features need to be applied or developed in the future. This paper describes the test hardware configurations, presents the results of all the analyses, and compares the results from the two analytical methods.

Hulka, James R.↗

NASA NTRS1980

Laser-heated thruster

The development of computer codes for the thrust chamber of a rocket of which the propellant gas is heated by a CW laser beam was investigated. The following results are presented: (1) simplified models of laser heated thrusters for approximate parametric studies and performance mapping; (3) computer programs for thrust chamber design; and (3) shock tube experiment to measure absorption coefficients. Two thrust chamber design programs are outlined: (1) for seeded hydrogen, with both low temperature and high temperature seeds, which absorbs the laser radiation continuously, starting at the inlet gas temperature; and (2) for hydrogen seeded with cesium, in which a laser supported combustion wave stands near the gas inlet, and heats the gas up to a temperature at which the gas can absorb the laser energy.

Kemp, N. H.↗

NASA NTRS1977

Liquid-hydrogen rocket engine development at Aerojet, 1944 - 1950

This program demonstrated the feasibility of virtually all the components in present-day, high-energy, liquid-rocket engines. Transpiration and film-cooled thrust chambers were successfully operated. The first liquid-hydrogen tests of the coaxial injector was conducted and the first pump to successfully produce high pressures in pumping liquid hydrogen was tested. A 1,000-lb-thrust gaseous propellant and a 3,000-lb-thrust liquid-propellant thrust chamber were operated satisfactorily. Also, the first tests were conducted to evaluate the effects of jet overexpansion and separation on performance of rocket thrust chambers with hydrogen-oxygen propellants.

Osborn, G. H.↗

NASA NTRS2004

Wavelength-Agile Optical Sensor for Exhaust Plume and Cryogenic Fluid Interrogation

Two optical sensors developed in UW-Madison labs were evaluated for their potential to characterize rocket engine exhaust plumes and liquid oxygen (LOX) fluid properties. The plume sensor is based on wavelength-agile absorption spectroscopy A device called a chirped white pulse emitter (CWPE) is used to generate the wavelength agile light, scanning, for example, 1340 - 1560 nm every microsecond. Properties of the gases in the rocket plume (for example temperature and water mole fraction) can be monitored using these wavelength scans. We have performed preliminary tests in static gas cells, a laboratory GOX/GH2 thrust chamber, and a solid-fuel hybrid thrust chamber, and these initial tests demonstrate the potential of the CWPE for monitoring rocket plumes. The LOX sensor uses an alternative to wavelength agile sensing: two independent, fixed-wavelength lasers are combined into a single fiber. One laser is absorbed by LOX and the other not: by monitoring the differential transmission the LOX concentration in cryogenic feed lines can be inferred. The sensor was successful in interrogating static LOX pools in laboratory tests. Even in ice- and bubble-laden cryogenic fluids, LOX concentrations were measured to better than 1% with a 3 microsec time constant.

Sanders, Scott T.↗

NASA NTRS1982

A technology data base for the design of 500 to 5000-lb thrust class liquid rocket engines utilizing hydrogen and oxygen as propellants

This paper presents an overview of the results of experimental evaluations of candidate designs for igniters, injectors, and propellant-cooled thrust chambers applicable to restartable high-performance, high-reliability upper-stage engines and to pulsing-type reaction control engines (RCE). Injection element types best suited for liquid, gas, and liquid/gas phase propellant supply are identified. The resulting interactions between element type, combustion efficiency, and chamber wall heating are compared. The distinction between thrust chamber design requirements for upper stage vs RCE applications as measured by cycle life requirements is translated into design configurations consisting of all-film-cooled, all-regeneratively-cooled, and composites of the two cooling approaches. The validity of the design approaches is confirmed by data from engine durability testing involving over 90,000 starts and 9,000 thermal cycles on RCE-type designs and multiple long-duration burns (up to 2,000 sec) on regeneratively cooled upper-stage designs.

Schoenman, L.↗

NASA NTRS1991

Transpiration cooled throat for hydrocarbon rocket engines

The objective for the Transpiration Cooled Throat for Hydrocarbon Rocket Engines Program was to characterize the use of hydrocarbon fuels as transpiration coolants for rocket nozzle throats. The hydrocarbon fuels investigated in this program were RP-1 and methane. To adequately characterize the above transpiration coolants, a program was planned which would (1) predict engine system performance and life enhancements due to transpiration cooling of the throat region using analytical models, anchored with available data; (2) a versatile transpiration cooled subscale rocket thrust chamber was designed and fabricated; (3) the subscale thrust chamber was tested over a limited range of conditions, e.g., coolant type, chamber pressure, transpiration cooled length, and coolant flow rate; and (4) detailed data analyses were conducted to determine the relationship between the key performance and life enhancement variables.

May, Lee R.↗

NASA NTRS2002

Evaluation of Impinging Stream Vortex Chamber Concepts for Liquid Rocket Engine Applications

To pursue technology developments for future launch vehicles, NASA/Marshall Space Flight Center (MSFC) is examining vortex chamber concepts for liquid rocket engine applications. Past studies indicated that the vortex chamber schemes potentially have a number of advantages over conventional chamber methods. Due to the nature of the vortex flow, relatively cooler propellant streams tend to flow along the chamber wall. Hence, the thruster chamber can be operated without the need of any cooling techniques. This vortex flow also creates strong turbulence, which promotes the propellant mixing process. Consequently, the subject chamber concepts not only offer system simplicity, but also enhance the combustion performance. Test results have shown that chamber performance is markedly high even at a low chamber length-to-diameter ratio (LD). This incentive can be translated to a convenience in the thrust chamber packaging. Variations of the vortex chamber concepts have been introduced in the past few decades. These investigations include an ongoing work at Orbital Technologies Corporation (ORBITEC). By injecting the oxidizer tangentially at the chamber convergence and fuel axially at the chamber head end, Knuth et al. were able to keep the wall relatively cold. A recent investigation of the low L/D vortex chamber concept for gel propellants was conducted by Michaels. He used both triplet (two oxidizer orifices and one fuel orifice) and unlike impinging schemes to inject propellants tangentially along the chamber wall. Michaels called the subject injection scheme an Impinging Stream Vortex Chamber (ISVC). His preliminary tests showed that high performance, with an Isp efficiency of 9295, can be obtained. MSFC and the U. S. Army are jointly investigating an application of the ISVC concept for the cryogenic oxygen/hydrocarbon propellant system. This vortex chamber concept is currently tested with gel propellants at AMCOM at Redstone Arsenal, Alabama. A version of this concept for the liquid oxygen (LOX) hydrocarbon fuel (RP-1) system has been derived from the one for the gel propellant. An unlike impinging injector was employed to deliver the propellants to the chamber. MSFC is also conducting an alternative injection scheme, called the chasing injector, associated with this vortex chamber concept. In this injection technique, both propellant jets and their impingement point are in the same chamber cross-sectional plane. Long duration tests (approximately up to 15 seconds) will be conducted on the ISVC to study the thermal effects. This paper will report the progress of the subject efforts at NASA Marshall Space Flight Center. Thrust chamber performance and thermal wall compatibility will be evaluated. The chamber pressures, wall temperatures, and thrust will be measured as appropriate. The test data will be used to validate CFD models, which, in turn, will be used to design the optimum vortex chambers. Measurements in the previous tests showed that the chamber pressures vary significantly with radius. This is due to the existence of the vortices in the chamber flow field. Hence, the combustion efficiency may not be easily determined from chamber pressure. For this project, measured thrust data will be collected. The performance comparison will be in terms of specific impulse efficiencies. In addition to the thrust measurements, several pressure and temperature readings at various locations on the chamber head faceplate and the chamber wall will be made. The first injector and chamber were designed and fabricated based on the available data and experience gained during gel propellant system tests by the U.S. Army. The alternate injector for the ISVC was also fabricated. Hot-fire tests of the vortex chamber are about to start and are expected to complete in February of 2003 at the TS115 facility of MSFC.

Trinh, Huu P.↗

NASA NTRS2015

Low Cost Upper Stage-Class Propulsion (LCUSP)

NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process can be sped up and improved with fewer errors to be accomplished in weeks instead of months.

Vickers, John↗

NASA NTRS1974

Nondestructive tests of regenerative chambers

The capabilities and limitations of nondestructive evaluation methods were studied to detect and locate bond deficiencies in regeneratively cooled thrust chambers for rocket engines. Flat test panels and a cylinder were produced to simulate regeneratively cooled thrust chamber walls. Planned defects with various bond integrities were produced in the panels to evaluate the sensitivity, accuracy, and limitations of nondestructive methods to define and locate bond anomalies. Holography, acoustic emission, and ultrasonic scan were found to yield sufficient data to discern bond quality when used in combination and in selected sequences. Bonding techniques included electroforming and brazing. Materials of construction included electroformed nickel bonded to Nickel 200 and OFHC copper, electroformed copper bonded to OFHC copper, and 300 series stainless steel brazed to OFHC copper. Variations in outer wall strength, wall thickness, and defect size were evaluated for nondestructive test response.

Malone, G. A.↗

NASA NTRS1972

Space Storable Propellant Performance Gas/Liquid Like-Doublet Injector Characterization

A 30-month applied research program was conducted, encompassing an analytical, design, and experimental effort to relate injector design parameters to simultaneous attainment of high performance and component (injector/thrust chamber) compatibility for gas/liquid space-storable propellants. The gas/liquid propellant combination selected for study was FLOX (82.6% F2)/ambient temperature gaseous methane. The injector pattern characterized was the like-(self)-impinging doublet. Program effort was apportioned into four basic technical tasks: injector and thrust chamber design, injector and thrust chamber fabrication, performance evaluation testing, and data evaluation and reporting. Analytical parametric combustion analyses and cold flow distribution and atomization experiments were conducted with injector segment models to support design of injector/thrust chamber combinations for hot fire evaluation. Hot fire tests were conducted to: (1) optimize performance of the injector core elements, and (2) provide design criteria for the outer zone elements so that injector/thrust chamber compatibility could be achieved with only minimal performance losses.

Falk, A. Y.↗

NASA NTRSDate not supplied

NASA's Compact High-Efficiency Rotating Detonation Rocket Engine for Mars Interplanetary Missions

NASA has successfully test fired a novel and compact liquid propulsion system known as a Rotating Detonation Rocket Engine. This is a specially designed ring-shaped thrust chamber that leverages additive manufacturing techniques and novel alloys such as GRCop-42 and GRX-810. The extreme combustion event, known as a detonation, reduces the combustion chamber length requirements down to a few inches while equivalent constant pressure rocket thrust chambers are on the order of feet. This is primarily due to rapid completion of combustion by the high-pressure detonation, an order of magnitude faster than deflagration combustion. In addition, the ring shape allows for rapid expansion of the combustion products. Depending on the thrust class and design supersonic area ratio, the full RDRE can be anywhere from 10% to 50% shorter than a traditional liquid rocket assuming the same exit diameter but is dependent on a number of design assumptions. This may enable substantial mass savings, cost savings, and broader design trade space for various mission architectures. Finally, the engine system has potential for higher Isp at identical average chamber pressure, which is currently being assessed by NASA. Experimental data obtained from testing in 2022 identified the feasibility of the novel propulsion system while multiple test series scheduled throughout 2023 and 2024 target closing the remaining critical technical gaps preventing widespread use of the technology amongst industry.

Thomas Teasley↗

NASA NTRS1989

Space Station Technology Summary

The completion of the Space Station Propulsion Advanced Technology Programs established an in-depth data base for the baseline gaseous oxygen/gaseous hydrogen thruster, the waste gas resistojet, and the associated system operations. These efforts included testing of a full end-to-end system at National Aeronautics and Space Administration (NASA)-Marshall Space Flight Center (MSFC) in which oxygen and hydrogen were generated from water by electrolysis at 6.89 MPa (1,000 psia), stored and fired through the prototype thruster. Recent end-to-end system tests which generate the oxygen/hydrogen propellants by electrolysis of water at 20.67 MPa (3,000 psia) were completed on the Integrated Propulsion Test Article (IPTA) at NASA-Johnson Space Center (JSC). Resistojet testing has included 10,000 hours of life testing, plume characterization, and electromagnetic interference (EMI) testing. Extensive 25-lbf thruster testing was performed defining operating performance characteristics across the required mixture ratio and thrust level ranges. Life testing has accumulated 27 hours of operation on the prototype thruster. A total of seven injectors and five thrust chambers were fabricated to the same basic design. Five injectors and three thrust chambers designed to incorporate improved life, performance, and producibility characteristics are ready for testing. Five resistojets were fabricated and tested, with modifications made to improve producibility. The lessons learned in the area of producibility for both the O2/H2 thrusters and for the resistojet have resolved critical fabrication issues. The test results indicate that all major technology issues for long life and reliability for space station application were resolved.

Iacabucci, R.↗

NASA NTRS1972

Rocket Combustion Instability Suppression With Cavity Resonators

Properly tuned Helmholtz resonator damping devices are an effective method for eliminating high frequency combustion instability in rocket engine thrust chambers. A program was implemented with the objective of extending Helmholtz resonator theory to thrust chamber conditions to establish a standard design procedure. By using systematic cold-flow testing and hot firings, empirical design equations were formulated. An effort is currently underway to extend the design theory to other types of acoustical damping devices such as quarter-wave tubes and slots.

R H Counts↗

NASA NTRS1992

Design issues for lunar in situ aluminum/oxygen propellant rocket engines

Design issues for lunar ascent and lunar descent rocket engines fueled by aluminum/oxygen propellant produced in situ at the lunar surface were evaluated. Key issues are discussed which impact the design of these rockets: aluminum combustion, throat erosion, and thrust chamber cooling. Four engine concepts are presented, and the impact of combustion performance, throat erosion and thrust chamber cooling on overall engine design are discussed. The advantages and disadvantages of each engine concept are presented.

Meyer, Michael L.↗

NASA NTRS1992

Design issues for lunar in situ aluminum/oxygen propellant rocket engines

Meyer, Michael L.↗