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At least 289 records · Page 16

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

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

Garcia, C. P.↗

An estimate of mean flow properties in a turbulent diffusion flame

Turbulent diffusion flames were computed while neglecting fluctuations of density, concentration and temperature, with reference to a central hydrogen jet issuing into a parallel coaxial airstream. An estimate for the time-average rate of fuel consumption was made, based mainly on dimensional analysis.

Bangert, L. H.↗

Quasi-steady plasma acceleration.

A coaxial plasma accelerator driven by protracted pulses of current in the range of 10,000 to 100,000 A and synchronized mass flows from 1.0 to 36 g/sec argon attains, after some tens of microseconds, a stable magnetoplasmadynamic acceleration mode. This 'quasi-steady' discharge form is characterized by constant terminal voltage and current, a diffuse, fixed current distribution within the discharge, and a steady plasma efflux at velocities of approximately 20 km/sec. Measured potential distributions reveal that the bulk of the arc voltage gradient, exclusive of the electrode falls, occurs within two diameters of the cathode, and is normal to it. The anode fall voltage varies inversely with local current density, implying substantially lower anode losses at higher power arc operation. Spectroscopic, potential, and velocity measurements indicate the existence of a characteristic mass flow rate for a given current, below which arc operation becomes erratic.

Jahn, R. G.↗

Aircraft thrust control

An integrated control system for coaxial counterrotating aircraft propulsors driven by a common gas turbine engine. The system establishes an engine pressure ratio by control of fuel flow and uses the established pressure ratio to set propulsor speed. Propulsor speed is set by adjustment of blade pitch.

Walker, Neil↗

Aircraft thrust control

An integrated control system for coaxial counterrotating aircraft propulsors driven by a common gas turbine engine. The system establishes an engine pressure ratio by control of fuel flow and uses the established pressure ratio to set propulsor speed. Propulsor speed is set by adjustment of blade pitch.

Bennett, George W.↗

Predictive Evaluations of Oxygen-Rich Hydrocarbon Combustion Gas-Centered Swirl Coaxial Injectors using a Flamelet-Based 3-D CFD Simulation Approach

NASA Marshall Space Flight Center (MSFC) has embarked upon a joint project with the Air Force to improve the state-of-the-art of space application combustion device design and operational understanding. One goal of the project is to design, build and hot-fire test a 40,000 pound-thrust Oxygen/Rocket Propellant-2 (RP-2) Oxygen-Rich staged engine at MSFC. The overall project goals afford the opportunity to test multiple different injector designs and experimentally evaluate the any effect on the engine performance and combustion dynamics. To maximize the available test resources and benefits, pre-test, combusting flow, Computational Fluid Dynamics (CFD) analysis was performed on the individual injectors to guide the design. The results of the CFD analysis were used to design the injectors for specific, targeted fluid dynamic features and the analysis results also provided some predictive input for acoustic and thermal analysis of the main Thrust Chamber Assembly (TCA). MSFC has developed and demonstrated the ability to utilize a computationally efficient, flamelet-based combustion model to guide the pre-test design of single-element Gas Centered Swirl Coaxial (GCSC) injectors. Previous, Oxygen/RP-2 simulation models utilizing the Loci-STREAM flow solver, were validated using single injector test data from the EC-1 Air Force test facility. The simulation effort herein is an extension of the validated, CFD driven, single-injector design approach applied to single injectors which will be part of a larger engine array. Time-accurate, Three-Dimensional, CFD simulations were performed for five different classes of injector geometries. Simulations were performed to guide the design of the injector to achieve a variety of intended performance goals. For example, two GCSC injectors were designed to achieve stable hydrodynamic behavior of the propellant circuits while providing the largest thermal margin possible within the design envelope. While another injector was designed to purposefully create a hydrodynamic instability in the fuel supply circuit as predicted by the CFD analysis. Future multi-injector analysis and testing will indicate what if any changes occur in the predicted behavior for the single-element injector when the same injector geometry is placed in a multi-element array.

Richardson, Brian R.↗

Experimental and Computational Studies of the Flow Over a Sting Mounted Planetary Probe Configuration

This paper summarizes the results of a series of experimental studies in the LENS shock tunnel and computations with DSMC and Navier Stokes codes which have been made to examine the aerothermal and flowfield characteristics of the flow over a sting-supported planetary probe configuration in hypervelocity air and nitrogen flows. The experimental program was conducted in the LENS hypervelocity shock tunnel at total enthalpies of 5and 10 MJkg for a range of reservoir pressure conditions from 70 to 500 bars. Heat transfer and pressure measurements were made on the front and rear face of the probe and along the supporting sting. High-speed and single shot schlieren photography were also employed to examine the flow over the model and the time to establish the flow in the base recirculation region. Predictions of the flowfield characteristics and the distributions of heat transfer and pressure were made with DSMC codes for rarefied flow conditions and with the Navier-Stokes solvers for the higher pressure conditions where the flows were assumed to be laminar. Analysis of the time history records from the heat transfer and pressure instrumentation on the face of the probe and in the base region indicated that the base flow was fully established in under 4 milliseconds from flow initiation or between 35 and 50 flow lengths based on base height. The measurements made in three different tunnel entries with two models of identical geometries but with different instrumentation packages, one prepared by NASA Langley and the second prepared by CUBRC, demonstrated good agreement between heat transfer measurements made with two different types of thin film and coaxial gage instrumentation. The measurements of heat transfer and pressure to the front face of the probe were in good agreement with theoretical predictions from both the DSMC and Navier Stokes codes. For the measurements made in low density flows, computations with the DSMC code were found to compare well with the pressure and heat transfer measurements on the sting, although the computed heat transfer rates in the recirculation region did not exhibit the same characteristics as the measurements. For the 10MJkg and 500 bar reservoir match point condition, the measurements and heat transfer along the sting from the first group of studies were in agreement with the Navier Stokes solutions for laminar conditions. A similar set of measurements made in later tests where the model was moved to a slightly different position in the test section indicated that the boundary layer in the reattachment compression region was close to transition or transitional where small changes in the test environment can result in larger than laminar heating rates. The maximum heating coefficients on the sting observed in the present studies was a small fraction of similar measurements obtained at nominally the same conditions in the HEG shock tunnel, where it is possible for transition to occur in the base flow, and in the low enthalpy studies conducted in the NASA Langley high Reynolds number Mach 10 tunnel where the base flow was shown to be turbulent. While the hybrid Navier- StokedDMSC calculations by Gochberg et al. (Reference 1) suggested that employing the Navier- Stokes calculations for the entire flowfield could be seriously in error in the base region for the 10 MJkg, 500 bar test case, similar calculations performed by Cornell, presented here, do not.

Holden, Michael S.↗

Performance and stability of a booster class LOX/hydrogen swirl coaxial-element injector

Initial tests were conducted with an axisymmetric subscale version of the Advanced Launch System (ALS) prototype injector, with a pattern of pressure-atomizing LOX-swirled injector elements flowing about 50 percent more propellant per element than the Space Shuttle Main Engine injector element. The swirl coax combustion was statistically stable and quiet with and without combustion stability aids. Artificial perturbations to assess dynamic stability generated overpressures from 2 to 15 percent of chamber pressure, and all combustion oscillations were damped within 3 millisec. Chug-free throttle was demonstrated to 65 percent of the nominal operating chamber pressure. Combustion performance in an ablative-lined chamber was calculated with both specific impulse and characteristic exhaust velocity, and averaged about 97 percent. Combustion performance of the injector element depended upon the momentum angle of the injected propellants rather than the shearing rate of the fuel on the oxidizer.

Hulka, J.↗

Los Alamos research in nozzle based coaxial plasma thrusters

The topics are presented in viewgraph form and include the following: research approach; perspectives on efficient magnetoplasmadynamic (MPD) operation; NASA and DOE supported research in ideal magnetohydrodynamic plasma acceleration and flow, electrode phenomena, and magnetic nozzles; and future research directions and plans.

Scheuer, Jay↗

RF multicoupler design techniques to minimize problems of corona, multipaction, and stability

A mathematical expression was derived describing multipacting and corona effects in a coaxial cavity. Both mechanical and electrical design techniques were investigated to minimize the susceptibility of coaxial cavity to corona and multipacting-type breakdown. To assist in the design of a multicoupler free from corona and multipactor breakdown, a flow chart obtained from the derived mathematical expression is included.

Hurley, H. S.↗

An analysis for high speed propeller-nacelle aerodynamic performance prediction. Volume 1: Theory and application

A computer program, the Propeller Nacelle Aerodynamic Performance Prediction Analysis (PANPER), was developed for the prediction and analysis of the performance and airflow of propeller-nacelle configurations operating over a forward speed range inclusive of high speed flight typical of recent propfan designs. A propeller lifting line, wake program was combined with a compressible, viscous center body interaction program, originally developed for diffusers, to compute the propeller-nacelle flow field, blade loading distribution, propeller performance, and the nacelle forebody pressure and viscous drag distributions. The computer analysis is applicable to single and coaxial counterrotating propellers. The blade geometries can include spanwise variations in sweep, droop, taper, thickness, and airfoil section type. In the coaxial mode of operation the analysis can treat both equal and unequal blade number and rotational speeds on the propeller disks. The nacelle portion of the analysis can treat both free air and tunnel wall configurations including wall bleed. The analysis was applied to many different sets of flight conditions using selected aerodynamic modeling options. The influence of different propeller nacelle-tunnel wall configurations was studied. Comparisons with available test data for both single and coaxial propeller configurations are presented along with a discussion of the results.

Egolf, T. Alan↗

Coaxial airblast atomizers

An experimental investigation was performed to quantify the characteristics of the sprays of coaxial injectors with particular emphasis on those aspects relevant to the performance of rocket engines. Measurements for coaxial air blast atomizers were obtained using air to represent the gaseous stream and water to represent the liquid stream. A wide range of flow conditions were examined for sprays with and without swirl for gaseous streams. The parameters varied include Weber number, gas flow rate, liquid flow rate, swirl, and nozzle geometry. Measurements were made with a phase Doppler velocimeter. Major conclusions of the study focused upon droplet size as a function of Weber number, effect of gas flow rate on atomization and spray spread, effect of nozzle geometry on atomization and spread, effect of swirl on atomization, spread, jet recirculation and breakup, and secondary atomization.

Hardalupas, Y.↗

Supersonic Coaxial Jet Experiment for CFD Code Validation

A supersonic coaxial jet facility has been designed to provide experimental data suitable for the validation of CFD codes used to analyze high-speed propulsion flows. The center jet is of a light gas and the coflow jet is of air, and the mixing layer between them is compressible. Various methods have been employed in characterizing the jet flow field, including schlieren visualization, pitot, total temperature and gas sampling probe surveying, and RELIEF velocimetry. A Navier-Stokes code has been used to calculate the nozzle flow field and the results compared to the experiment.

Cutler, A. D.↗

Damping characteristics of dashpots

An investigation of the damping characteristics of dashpots was carried out combining theory and experiment. Laminar flow was assumed and three equations for the steady velocity of a piston moving in a cylinder filled with liquid were derived. In the first equation, the piston was assumed coaxial in the cylinder and, in the second equation, the piston was assumed eccentric in the cylinder with an element of the piston in contact with the cylinder wall. The third equation is for a piston of circular cross section in an elliptical cylinder. Experiments showed that the piston is normally eccentric in the cylinder. The pistons tested were 1.25 and 2 inches in diameter 0.062 to 1.00 inch long, and the clearances varied from 1.36 to 5.16 x 10 to the 3rd power inch. The difference in pressure on the two sides of the piston varied from about 2 to 55 pounds per square inch. The piston velocities for each assembly were measured with damping liquids of three different viscosities. At high piston velocities, when turbulent flow exists, the observed velocities were much lower than the velocities calculated on the basis of laminar flow. Results for a wide range of Reynolds numbers are presented in graphical form.

INSTRUMENTS-MICROMETERS↗

CFD Simulation of Liquid Rocket Engine Injectors

Detailed design issues associated with liquid rocket engine injectors and combustion chamber operation require CFD methodology which simulates highly three-dimensional, turbulent, vaporizing, and combusting flows. The primary utility of such simulations involves predicting multi-dimensional effects caused by specific injector configurations. SECA, Inc. and Engineering Sciences, Inc. have been developing appropriate computational methodology for NASA/MSFC for the past decade. CFD tools and computers have improved dramatically during this time period; however, the physical submodels used in these analyses must still remain relatively simple in order to produce useful results. Simulations of clustered coaxial and impinger injector elements for hydrogen and hydrocarbon fuels, which account for real fluid properties, is the immediate goal of this research. The spray combustion codes are based on the FDNS CFD code' and are structured to represent homogeneous and heterogeneous spray combustion. The homogeneous spray model treats the flow as a continuum of multi-phase, multicomponent fluids which move without thermal or velocity lags between the phases. Two heterogeneous models were developed: (1) a volume-of-fluid (VOF) model which represents the liquid core of coaxial or impinger jets and their atomization and vaporization, and (2) a Blob model which represents the injected streams as a cloud of droplets the size of the injector orifice which subsequently exhibit particle interaction, vaporization, and combustion. All of these spray models are computationally intensive, but this is unavoidable to accurately account for the complex physics and combustion which is to be predicted, Work is currently in progress to parallelize these codes to improve their computational efficiency. These spray combustion codes were used to simulate the three test cases which are the subject of the 2nd International Workshop on-Rocket Combustion Modeling. Such test cases are considered by these investigators to be very valuable for code validation because combustion kinetics, turbulence models and atomization models based on low pressure experiments of hydrogen air combustion do not adequately verify analytical or CFD submodels which are necessary to simulate rocket engine combustion. We wish to emphasize that the simulations which we prepared for this meeting are meant to test the accuracy of the approximations used in our general purpose spray combustion models, rather than represent a definitive analysis of each of the experiments which were conducted. Our goal is to accurately predict local temperatures and mixture ratios in rocket engines; hence predicting individual experiments is used only for code validation. To replace the conventional JANNAF standard axisymmetric finite-rate (TDK) computer code 2 for performance prediction with CFD cases, such codes must posses two features. Firstly, they must be as easy to use and of comparable run times for conventional performance predictions. Secondly, they must provide more detailed predictions of the flowfields near the injector face. Specifically, they must accurately predict the convective mixing of injected liquid propellants in terms of the injector element configurations.

Farmer, Richard↗

Combustion Zone Characterization of GO2/GH2 Rocket Using Laser-Induced Fluorescence of OH

A series of studies were undertaken to measure various parameters such as velocity, species concentration, and temperature downstream of a shear coaxial injector in an optically accessible uni-element rocket chamber. Techniques applied include: laser Doppler velocimetry (LDV) for velocity; laser light scattering (LLS) for flow visualization and estimating mixture fraction and density; laser induced fluorescence (LIF) of hydroxyl radials (OH) to determine the characteristics and extent of the reaction zone; and Raman spectroscopy to measure major species concentration and temperature.

Moser, M. D.↗

Spray Diagnostics in Rocket Engines Using Phase Doppler Analyzer

Characteristics such as drop velocity, drop size, number density, volume flow rate, volume flux, and evaporation rate of the fuel spray in a rocket engine are directly related to engine performance. Several studies of shear coaxial atomization have been done in the past. However, additional work related to sprays at supercritical and transcritical conditions would be useful. The author undertook a study of the feasibility of using a phase Doppler particle analyzer (PDPA) for spray measurements in rocket engines as a part of the Summer Faculty Fellowship Program at the NASA Marshall Space Flight Center. The PDPA is a single particle counter (SPC) system based on light scattering from spherical particles. The PDPA instrument is based on refractive and reflective scattering as opposed to other instruments based on diffractive scattering. The main advantage of the PDPA instrument is its ability to provide point-wise information. The following sections describe the principle of operation of the PDPA system and the data obtained using a PDPA instrument in a spray formed by a commercially available fuel injection nozzle.

Isaac, Kakkattukuzhy M.↗

Aerodynamics and Aeroacoustic Sources of a Coaxial Rotor

Vehicles with coaxial, contra-rotating rotor systems (CACR) are being considered for a range of applications. Design parameters are identified that effect the fundamental aerodynamics and fluid dynamic features of a CACR in hover, vertical, and edgewise flight. Understanding the fluid dynamic features is a precursor to studying the aeroacoustics of a coaxial rotor. Rotor performance was computed initially using Navier-Stokes solver with prescribed blade section aerodynamic properties, the results validated against generic experimental test cases. Using a A 2D potential flow code and 2D OVERFLOW compressible-flow Navier-Stokes solver, the fluid dynamics of blade interactions was simplified and broken into a 2D blade crossing problem, with crossing locations and velocity fields from the rotor results to understand circulation, thickness, compressibility, shed vorticity, downwash, and viscosity effects. A calculation tool has been developed to identify time and location of blade overlap and BVI time location for CACR. Specific aerodynamic phenomena that occur for each noise source relevant to CACR are presented, along with computational tools to predict these occurrences.

Aeroacoustic↗