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This task is to hot-fire test an existing Space Launch Mission (SLM) injector that is applicable for all expander cycle engines being considered for the exploration upper stage. The work leverages investment made in FY 2013 that was used to additively manufacture three injectors (fig. 1) all by different vendors..
The high total temperatures or total enthalpies required to duplicate the high-speed flight conditions in ground experiments often place stringent requirements on the material selection and cooling needs for the test articles and intrusive flow diagnostic equipment. Furthermore, for internal flows, these conditions often complicate the use of nonintrusive diagnostics that need optical access to the test section and interior portions of the flowpath. Because of the technical challenges and increased costs associated with experimentation at high values of total enthalpy, an attempt is often made to reduce it. This is the case for the Enhanced Injection and Mixing Project (EIMP) currently underway in the Arc-Heated Scramjet Test Facility at the NASA Langley Research Center. The EIMP aims to investigate supersonic combustion ramjet (scramjet) fuel injection and mixing physics, improve the understanding of underlying physical processes, and develop enhancement strategies and functional relationships between mixing performance and losses relevant to flight Mach numbers greater than 8. The experiments will consider a "direct-connect" approach and utilize a Mach 6 nozzle to simulate the combustor entrance flow of a scramjet engine. However, while the value of the Mach number is matched to that expected at the combustor entrance in flight, the maximum value of the total enthalpy for these experiments is limited by the thermal-structural limits of the uncooled experimental hardware. Furthermore, the fuel simulant is helium, not hydrogen. The use of "cold" flows and non-reacting mixtures of fuel simulants for mixing experiments is not new and has been extensively utilized as a screening technique for scramjet fuel injectors. In this study, Reynolds-averaged simulations are utilized (RAS) to systematically verify the implicit assumptions used by the EIMP. This is accomplished by first performing RAS of mixing for two injector configurations at planned nominal experimental conditions. The mixing parameters of interest, such as mixing efficiency and total pressure recovery, are then computed and compared to the values obtained from RAS under the true enthalpy conditions and using helium and hydrogen. Finally, the impact of combustion on mixing, often deemed small enough to neglect at hypervelocity conditions, is assessed by comparing the results obtained from the hydrogen-fueled reacting and non-reacting RAS. For reacting flows, in addition to mixing efficiency and total pressure recovery, the combustion efficiency and thrust potential are also considered. In all of the simulations, the incoming air Mach number and the fuel-to-air ratio are the same, while the total pressure, total enthalpy, and the fuel simulant vary depending on the case considered. It is found that under some conditions the "cold" flow experiments are a good approximation of the flight.
Film cooling is used in a wide variety of engineering applications for protection of surfaces from hot or combusting gases. The design of more efficient thin film cooling geometries/configurations could be facilitated by an ability to accurately model and predict the effectiveness of current designs using computational fluid dynamics (CFD) code predictions. Hence, a benchmark set of flow field property data were obtained for use in assessing current CFD capabilities and for development of better turbulence models. Both Particle Image Velocimetry (PIV) and spontaneous rotational Raman scattering (SRS) spectroscopy were used to acquire high quality, spatially-resolved measurements of the mean velocity, turbulence intensity and also the mean temperature and normalized root mean square (rms) temperatures in a single injector cooling flow arrangement. In addition to flowfield measurements, thermocouple measurements on the plate surface enabled estimates of the film effectiveness. Raman spectra in air were obtained across a matrix of radial and axial locations downstream from a 68.07 mm square nozzle blowing heated air over a range of temperatures and Mach numbers, across a 30.48 cm long plate equipped with a single injector cooling hole. In addition, both centerline streamwise 2-component PIV and cross-stream 3-component Stereo PIV data at 15 axial stations were collected in the same flows. The velocity and temperature data were then compared against Wind-US CFD code predictions for the same flow conditions. The results of this and planned follow-on studies will support NASA's development and assessment of turbulence models for heated flows.
Film cooling is used in a wide variety of engineering applications for protection of surfaces from hot or combusting gases. The design of more efficient thin film cooling geometries/configurations could be facilitated by an ability to accurately model and predict the effectiveness of current designs using computational fluid dynamics (CFD) code predictions. Hence, a benchmark set of flow field property data were obtained for use in assessing current CFD capabilities and for development of better turbulence models. Both Particle Image Velocimetry (PIV) and spontaneous rotational Raman scattering (SRS) spectroscopy were used to acquire high quality, spatially-resolved measurements of the mean velocity, turbulence intensity and also the mean temperature and normalized root mean square (rms) temperatures in a single injector cooling flow arrangement. In addition to flowfield measurements, thermocouple measurements on the plate surface enabled estimates of the film effectiveness. Raman spectra in air were obtained across a matrix of radial and axial locations downstream from a 68.07 mm square nozzle blowing heated air over a range of temperatures and Mach numbers, across a 30.48cm long plate equipped with a single injector cooling hole. In addition, both centerline streamwise 2-component PIV and cross-stream 3-component Stereo PIV data at 15 axial stations were collected in the same flows. The velocity and temperature data were then compared against Wind-US CFD code predictions for the same flow conditions. The results of this and planned follow-on studies will support NASA's development and assessment of turbulence models for heated flows.
Film cooling is used in a wide variety of engineering applications for protection of surfaces from hot or combusting gases. The design of more efficient thin film cooling geometries/configurations could be facilitated by an ability to accurately model and predict the effectiveness of current designs using computational fluid dynamics (CFD) code predictions. Hence, a benchmark set of flow field property data were obtained for use in assessing current CFD capabilities and for development of better turbulence models. Both Particle Image Velocimetry (PIV) and spontaneous rotational Raman scattering (SRS) spectroscopy were used to acquire high quality, spatially-resolved measurements of the mean velocity, turbulence intensity and also the mean temperature and normalized root mean square (rms) temperatures in a single injector cooling flow arrangement. In addition to flowfield measurements, thermocouple measurements on the plate surface enabled estimates of the film effectiveness. Raman spectra in air were obtained across a matrix of radial and axial locations downstream from a 68.07 mm square nozzle blowing heated air over a range of temperatures and Mach numbers, across a 30.48cm long plate equipped with a single injector cooling hole. In addition, both centerline streamwise 2-component PIV and cross-stream 3-component Stereo PIV data at 15 axial stations were collected in the same flows. The velocity and temperature data were then compared against Wind-US CFD code predictions for the same flow conditions. The results of this and planned follow-on studies will support NASA's development and assessment of turbulence models for heated flows.
This paper reports results for a 7-point lean direct injector (LDI) array for a particular configuration. The LDI configuration in this study used a 60 degrees center pilot swirler and 52.5 degrees on the six outer swirlers. Chemiluminescence images of C2 and CH were collected at a frame rate of 25 Hz using an intensified CCD camera. Narrow bandwidth filters were coupled with the CCD camera in order to spectrally isolate C2 and CH signals. C2 was captured at 515 nm, and the CH signal was acquired at 430 nm. Six inlet conditions were considered in this study, all with the same inlet pressure, 75 psia, and same inlet temperature, 800 degcrees Fahrenheit. These conditions aimed to observe the effect of equivalence ratio, fuel staging, and reference velocity on C2 and CH emissions. Based on the chemiluminescence images, the changes in the inlet conditions was evident in both the pilot and outers. Additionally, the pilot (center injector element) appeared well isolated from the six outer elements under all test conditions.
This paper continues a parametric study in which we consider the effect of air swirler configuration on the flame structure and combustor performance using a circular 7-point Lean Direct Injector Array for gas turbine applications. The injector array consists of a center swirler element surrounded by six swirler elements. Parameters considered in this study include swirler angle (60° or 52°), handedness (co-swirling or counter-swirling) and center swirler offset. The primary focus considers flame stability, comparing four key air swirler configurations: for 1) fuel-lean flames; 2) high cold flow air reference velocity flames. We determined that the baseline swirler configuration had the best lean stability and could sustain the highest reference velocity. For this baseline configuration, we also compare the lean-blowout limits of four aircraft gas turbine reference fuels. With regard to lean blow-out, we determined that C4 could sustain the leanest flame, followed closely by A2. A1 was a poor performer.
This paper continues a parametric study in which we consider the effect of air swirler configuration on the flame structure and combustor performance using a circular 7-point Lean Direct Injector Array for gas turbine applications. The injector array consists of a center swirler element surrounded by six swirler elements. Parameters considered in this study include swirler angle (60° or 52°), handedness (co-swirling or counter-swirling) and center swirler offset. The primary focus considers flame stability, comparing four key air swirler configurations: for 1) fuel-lean flames; 2) high cold flow air reference velocity flames. We determined that the baseline swirler configuration had the best lean stability and could sustain the highest reference velocity. For this baseline configuration, we also compare the lean-blowout limits of four aircraft gas turbine reference fuels. With regard to lean blow-out, we determined that C4 could sustain the leanest flame, followed closely by A2. A1 was a poor performer.
A single-injector cooling flow into a heated crossflow was used as a validation case for large eddy simulations (LES) from two high-order CFD codes with comparisons to a state-of-the-art Reynolds averaged Navier-Stokes (RANS) turbulence model. The focus of this paper is on the validation of LES for one of the high-order CFD codes, namely the GFR (Glenn Flux Reconstruction) code that is being developed at NASA Glenn Research Center. Fourth-order LES were performed for the single-injector cooling flow configuration at blowing ratios of both 1.0 and 2.0, and a fifth-order LES was also performed with a blowing ratio of 1.0. The GFR simulations agree very well with the experiment mean quantities and reasonably well with the experiment turbulence quantities. The LES solutions from GFR and the other high-order CFD code, FDL3DI, agreed very closely for nearly every flow quantity examined, despite the fact that these two codes use completely different numerical methods, different grid geometries and domains, and different inflow boundary conditions. Finally, both LES show a significant accuracy improvement over RANS turbulence models for flows with large temperature gradients, where the standard gradient diffusion approximation is insufficient for temperature predictions.
A single-injector cooling flow into a heated crossflow was used as a validation case for large eddy simulations (LES) from two high-order CFD codes with comparisons to a state-of-the-art Reynolds averaged Navier-Stokes (RANS) turbulence model. The focus of this paper is on the validation of LES for one of the high-order CFD codes, namely the GFR (Glenn Flux Reconstruction) code that is being developed at NASA Glenn Research Center. Fourth-order LES were performed for the single-injector cooling flow configuration at blowing ratios of both 1.0 and 2.0, and a fifth-order LES was also performed with a blowing ratio of 1.0. The GFR simulations agree very well with the experiment mean quantities and reasonably well with the experiment turbulence quantities. The LES solutions from GFR and the other high-order CFD code, FDL3DI, agreed very closely for nearly every flow quantity examined, despite the fact that these two codes use completely different numerical methods, different grid geometries and domains, and different inflow boundary conditions. Finally, both LES show a significant accuracy improvement over RANS turbulence models for flows with large temperature gradients, where the standard gradient diffusion approximation is insufficient for temperature predictions.
A finite volume-based network flow modeling tool, Generalized Fluid System Simulation Program (GFSSP), was used to simulate the no-vent filling of a cryogenic tank with a thermodynamic vent system assisted injector. The tank was discretized into nodes in the radial and axial directions to calculate two-dimensional axisymmetric flow with heat transfer between the solid wall and fluid. The nodes are connected by branches where momentum equations are solved to calculate the flowrates. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The energy conservation equations at the solid nodes were solved to calculate the temperature of the solid wall. The system of equations was solved by a combination of successive substitution and simultaneous Newton-Raphson method. The numerical model accounts for a) different regimes of pool boiling heat transfer, b) condensation of vapor around the spray droplets, c) condensation of vapor at the interface of the cooled injector and ullage, and d) condensation at the liquid-vapor interphase. The numerical predictions of tank pressure, filling rate, and wall temperatures were compared with the test data. The paper also presents the effect of nodal discretization by comparing the results of the 1D and 2D models and examines the effect of the droplet diameter on tank filling.
A finite volume-based network flow modeling tool, Generalized Fluid System Simulation Program (GFSSP), was used to simulate the no-vent filling of a cryogenic tank with a thermodynamic vent system assisted injector. The tank was discretized into nodes in the radial and axial directions to calculate two-dimensional axisymmetric flow with heat transfer between the solid wall and fluid. The nodes are connected by branches where momentum equations are solved to calculate the flowrates. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The energy conservation equations at the solid nodes were solved to calculate the temperature of the solid wall. The system of equations was solved by a combination of successive substitution and simultaneous Newton-Raphson method. The numerical model accounts for a) different regimes of pool boiling heat transfer, b) condensation of vapor around the spray droplets, c) condensation of vapor at the interface of the cooled injector and ullage, and d) condensation at the liquid-vapor interphase. The numerical predictions of tank pressure, filling rate, and wall temperatures were compared with the test data. The paper also presents the effect of nodal discretization by comparing the results of the 1D and 2D models and examines the effect of the droplet diameter on tank filling.
Mixing efficiency is obtained for a strut fuel injector at hypervelocity flow conditions by using large-eddy simulations (LES), Reynolds-averaged simulations (RAS), and experiments. The injector and flow conditions have been previously investigated by using RAS and experiments as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center (LaRC). Because the fidelity of LES is a strong function of the grid, the mixing efficiency is obtained on two grids, the coarser of which is a factor of two coarser in each of the three dimensions with respect to the fine grid. The RAS uses the two-equation linear eddy viscosity and diffusivity modeling of Menter. In RAS, the species diffusivity model exhibits a strong dependence on the turbulent Schmidt number, which is often adjusted until some metric of engineering interest, such as the mixing efficiency, matches the experimental data. In the absence of experimental data, scale-resolving simulations, such as LES, have been proposed as surrogates for experiments that could provide the data needed to “calibrate” the turbulent Schmidt number in the RAS models. This approach is followed because LES requires significantly more computational resources (CPU, data storage, and time) than RAS, making it prohibitive for use in many engineering applications and specifically for parameter exploration or optimization. Here we examine the mixing efficiency obtained from several RAS with different values of the turbulent Schmidt number, and compare the results with those obtained from the LES and experiments. In addition, the least squares fitting approach was used to demonstrate how to obtain an estimate for the turbulent Schmidt number from LES analytically. These estimates were then used together with prior knowledge about RAS model sensitivity to select a turbulence model that was expected to best match the LES data.
Mixing efficiency is obtained for a strut fuel injector at hypervelocity flow conditions by using large-eddy simulations (LES), Reynolds-averaged simulations (RAS), and experiments. The injector and flow conditions have been previously investigated by using RAS and experiments as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center (LaRC). Because the fidelity of LES is a strong function of the grid, the mixing efficiency is obtained on two grids, the coarser of which is a factor of two coarser in each of the three dimensions with respect to the fine grid. The RAS uses the two-equation linear eddy viscosity and diffusivity modeling of Menter. In RAS, the species diffusivity model exhibits a strong dependence on the turbulent Schmidt number, which is often adjusted until some metric of engineering interest, such as the mixing efficiency, matches the experimental data. In the absence of experimental data, scale-resolving simulations, such as LES, have been proposed as surrogates for experiments that could provide the data needed to “calibrate” the turbulent Schmidt number in the RAS models. This approach is followed because LES requires significantly more computational resources (CPU, data storage, and time) than RAS, making it prohibitive for use in many engineering applications and specifically for parameter exploration or optimization. Here we examine the mixing efficiency obtained from several RAS with different values of the turbulent Schmidt number, and compare the results with those obtained from the LES and experiments. In addition, the least squares fitting approach was used to demonstrate how to obtain an estimate for the turbulent Schmidt number from LES analytically. These estimates were then used together with prior knowledge about RAS model sensitivity to select a turbulence model that was expected to best match the LES data.
Single fuel-vaporizing combustor with injectors adapted for gaseous hydrogen
Injector evaluation in 2400-pound-thrust rocket engine using liquid oxygen and liquid ammonia
Performance and stability characteristics of rocket engine injectors using liquid oxygen propellant
Spray properties of unlike impinging streams of nonreacting fluids for design application to liquid propellant rocket engine injector