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At least 307 records · Page 17

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NASA NTRS1988

Development of an advanced failure detection algorithm for the SSME

Since ground testing of the Space Shuttle Main Engine began in 1975, a multifaceted detection/shutdown system has been used to detect engine anomalies and initiate shutdown. In spite of this system, 27 major incidents have occurred since testing began. Although a small percentage of over 1200 successful hot fire tests, such incidents can result in significant cost and schedule impacts. Therefore, an advanced failure detection algorithm has been developed which consists of three detection approaches designed for a failure characteristic that has been previously documented. Simulations using sensor data from five incident tests show the algorithm detecting an anomally and signalling shutdown prior to the redline cutoff time. The foundation elements of the algorithm and its functioning are described.

Norman, A.↗

NASA NTRS1988

SSME 3-D Turnaround Duct flow analysis - CFD predictions

CFD analysis is presently employed to obtain an improved flowfield for an individual flowpath in the case of the Space Shuttle Main Engine's High Pressure Fuel Turbopump Turn-Around Duct (TAD), which conducts the flow exiting from the gas turbines into the fuel bowl. It is demonstrated that the application of CFD to TAD flow analysis, giving attention to the duct's configuration and to the number, shape, and alignment of the diffuser struts, can enhance understanding of flow physics and result in improved duct design and performance.

Brankovic, Andreja↗

NASA NTRS1988

3-D stator-rotor interaction of the SSME

The time-dependent stator-rotor interaction pattern of the Space Shuttle Main Engine's High-Pressure Fuel-Side Turbopump is presently studied by a multiple-zone solution algorithm, for both a two-dimensional case with 2:3 stator-rotor blade ratio and a three-dimensional case with a 1:1 ratio. A time-centered differencing scheme is used for temporal discretization, together with a sliding-grid multiple-zone solution method and an extended two-equation turbulence model with a wall function approach. The algorithm's accuracy is tested against experimental data.

Chen, Yen-Sen↗

NASA NTRS1988

Duct flow nonuniformities for Space Shuttle Main Engine (SSME)

Analytical capabilities for modeling hot gas flow on the fuel side of the Space Shuttle Main Engines are developed. Emphasis is placed on construction and documentation of a computational grid code for modeling an elliptical two-duct version of the fuel side hot gas manifold. Computational results for flow past a support strut in an annular channel are also presented.

Source record↗

NASA NTRS1989

Advanced single crystal for SSME turbopumps

The objective of this program was to evaluate the influence of high thermal gradient casting, hot isostatic pressing (HIP) and alternate heat treatments on the microstructure and mechanical properties of a single crystal nickel base superalloy. The alloy chosen for the study was PWA 1480, a well characterized, commercial alloy which had previously been chosen as a candidate for the Space Shuttle Main Engine high pressure turbopump turbine blades. Microstructural characterization evaluated the influence of casting thermal gradient on dendrite arm spacing, casting porosity distribution and alloy homogeneity. Hot isostatic pressing was evaluated as a means of eliminating porosity as a preferred fatigue crack initiation site. The alternate heat treatment was chosen to improve hydrogen environment embrittlement resistance and for potential fatigue life improvement. Mechanical property evaluation was aimed primarily at determining improvements in low cycle and high cycle fatigue life due to the advanced processing methods. Statistically significant numbers of tests were conducted to quantitatively demonstrate life differences. High thermal gradient casting improves as-cast homogeneity, which facilitates solution heat treatment of PWA 1480 and provides a decrease in internal pore size, leading to increases in low cycle and high cycle fatigue lives.

Fritzemeier, L. G.↗

NASA NTRS1989

3D computational analyses for SSME internal flows

Two qualities of the turbulent flow of hot gases in liquid fueled rocket engines that affect the selection and performance of turbulence models used in computational fluid analyses of the flow are curvature of the flow passages and rotation of the flow. Three configurations which represent these conditions and for which experimental data are available are subjected to three dimensional computational analyses using both the standard k - epsilon and a multiple-time-scale turbulence models. It is found that the multiple-time-scale model is better able to predict overall flow features, especially where regions of separated flow are present.

Chen, C. P.↗

NASA NTRS1989

A combined Eulerian-Lagrangian two-phase flow analysis of SSME HPOTP nozzle plug trajectories. II - Results

An analysis of Space Shuttle Main Engine high-pressure oxygen turbopump nozzle plug trajectories has been performed, using a Lagrangian method to track nozzle plug particles expelled from a turbine through a high Reynolds number flow in a turnaround duct with turning vanes. Axisymmetric and parametric analyses reveal that if nozzle plugs exited the turbine they would probably impact the LOX heat exchanger with impact velocities which are significantly less than the penetration velocity. The finding that only slight to moderate damage will result from nozzle plug failure in flight is supported by the results of a hot-fire engine test with induced nozzle plug failures.

Mcconnaughey, P. K.↗

NASA NTRS1989

SSME Alternate Turbopump Development Program: Design verification specification for high-pressure fuel turbopump

The design and verification requirements are defined which are appropriate to hardware at the detail, subassembly, component, and engine levels and to correlate these requirements to the development demonstrations which provides verification that design objectives are achieved. The high pressure fuel turbopump requirements verification matrix provides correlation between design requirements and the tests required to verify that the requirement have been met.

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NASA NTRS1989

SSME LOX post flow analysis/fluid structure interaction. Volume 2: Fluid structure interaction

The progress made in resolving the computational issues associated with modeling high temperature and pressure viscous flows in advanced propulsion systems is documented. An overview of adaptive computational methods for various classes of fluid-structure interaction problems is presented. The key features associated with several approaches are outlined and the advantages/disadvantages of each are summarized. A mathematical formulation is presented for general fluid-structure interaction problems with a moving domain. The two adaptive approaches are discussed used in solving the benchmark problems. The first scheme is a user interactive scheme which is quite versatile and easy to implement but requires an excessive amount of monitoring by the operator and is computationally inefficient. The second method is a new, local remeshing method for handling a general class of fluid-structure interaction problems. This method couples many of the attractive features of other approaches into a computationally efficient and versatile method. The results obtained for two test cases are presented. Results from both the user interactive and local remeshing procedure are described. The current status of the project and future goals to be completed are summarized.

Source record↗

NASA NTRS1990

Heat transfer and pressure measurements for the SSME fuel-side turbopump

A measurement program is currently underway at the Calspan-UB Research Center (CUBRC) which utilizes the Rocketdyne two-state fuel-side turbine with the engine geometric configuration reproduced. This is a full two-state turbine for which the vane rows and the blades are the engine hardware currently used on the Space Shuttle turbopump. A status report is provided for the experimental program and a description of the instrumentation and the measurements to be performed. The specific items that will be illustrated and described are as follows: (1) the gas flow path, (2) the heat-flux instrumentation, (3) the surface-pressure instrumentation, (4) the experimental conditions for which data will be obtained, and (5) the specific measurements that will be performed.

Dunn, Michael G.↗

NASA NTRS1990

Analysis of coolant flow and heat transfer in the SSME HPOTP Number 4 bearing assembly

The PHOENICS code has been applied to simulate the flow of liquid oxygen through the number 4 ball bearing assembly of the Space Shuttle Main Engine High-Pressure Oxidizer Turbopump. The Body-Fitted Coordinate system capability of PHOENICS was utilized to create a geometrically accurate model. Effects accounted for by the model include the rotation rate of the calculation domain, viscous heating in the liquid oxygen and two-phase effects due to LOX boiling. A separation program was used to account for conduction within a ball bearing element which was coupled with the PHOENICS flow and heat transfer analysis. Solutions have been obtained for the velocity and temperature fields within the LOX coolant and the temperature within the ball element. The predicted ball temperatures indicate that the coolant is boiling in the region near the ball surface.

Owens, S. F.↗

NASA NTRS1990

Numerical investigation of the transient SSME fuel preburner combustor flowfield

A computational fluid dynamics (CFD) model with finite-rate reactions, FDNS2DR, has been developed to study the start transient of the Space Shuttle Main Engine Fuel Preburner (FPB) operation. This design tool can predict accurately the severe thermal gradients which are impressed upon the fuel preburner and turbine during the start transient. An axisymmetric configuration with a grid size of 68 x 45 is used to represent the FPB flowfield. The transient upstream boundary conditions are obtained from a one-dimensional Digital Transient Model simulation to better represent the actual operation. The results of the CFD calculation show temperature spikes near the FPB exit whose timing and magnitude agree well with those of the measured turbine inlet temperature data.

Wang, Ten-See↗

NASA NTRS1990

Computational flow simulation of liquid oxygen in a SSME preburner injector element LOX post

Liquid oxygen (LOX) is simulated as an incompressible flow through a Space Shuttle main engine fuel preburner injector element LOX post for the full range of operating conditions. Axial profiles of axial velocity and static pressure are presented. For each operating condition analyzed, the minimum pressure downstream of the orifice is compared to the vapor pressure to determine if cavitation could occur. Flow visualization is provided by velocity vectors and stream function contours. The results indicate that the minimum pressure is too high for cavitation to occur. To establish confidence in the CFD analysis, the simulation is repeated with water flow through a superscaled LOX post and compared with experimental results. The agreement between calculated and experimental results is very good.

Rocker, Marvin↗

NASA NTRS1989

LEADER - An integrated engine behavior and design analyses based real-time fault diagnostic expert system for Space Shuttle Main Engine (SSME)

The LEADER expert system has been developed for automatic learning tasks encompassing real-time detection, identification, verification, and correction of anomalous propulsion system operations, using a set of sensors to monitor engine component performance to ascertain anomalies in engine dynamics and behavior. Two diagnostic approaches are embodied in LEADER's architecture: (1) learning and identifying engine behavior patterns to generate novel hypotheses about possible abnormalities, and (2) the direction of engine sensor data processing to perform resoning based on engine design and functional knowledge, as well as the principles of the relevant mechanics and physics.

Gupta, U. K.↗

NASA NTRS1990

Internal flow measurements of the SSME fuel preburner injector element using real time neutron radiography

Due to observations of unsteady flow in the Space Shuttle Main Engine fuel preburner injector element, several flow studies have been performed. Real time neutron radiography tests were recently completed. This technique provided real time images of MiL-c-7024 and Freon-22 flow through an aluminum liquid oxygen post model at three back pressures (0, 150, and 545 psig) and pressure drops up to 1000 psid. Separated flow appeared only while operating at back pressures of 0 and 150 psig. The behavior of separated flow was similar to that observed for water in a 3x acrylic model of the LOX post. On the average, separated flow appeared to reattach near the exit of the post when the ratio of pressure drop to supply pressure was about 0.75.

Lindsay, John T.↗

NASA NTRS1990

Aerothermal environment induced by mismatch at the SSME main combustion chamber-nozzle joint

The computational study reported here is motivated by a Space Shuttle main engine hardware problem detected in post-flight and post-test inspections. Of interest are the potential for hot gas ingestion into the joint (G15) at the main combustion chamber-to-nozzle interface and the effect of particular goemetric nonuniformities on that gas ingestion. The flowfield in the G15 region involves supersonic flow past a rounded forward facing step preceded by a deep narrow cavity. This paper describes the physical problem associated with joint G15 and computational investigations of the G15 aerothermal environment. The associated flowfield was simulated in two and three space dimensions using the United Solutions Algorithm (USA) computational fluid dynamics code series. A benchmark calculation of experimentally measured supersonic flow over of a square cavity was performed to demonstrate the accuracy of the USA code in analyzing flows similar to the G15 computational flowfield. The G15 results demonstrate the mechanism for hot gas ingestion into the joint and reveal the sensitivity to salient geometric nonuniformities.

Mcconnaughey, H. V.↗

NASA NTRS1990

The simulation of fluid dynamic uncertainties in the SSME turbopump

The aerodynamic uncertainties in the reusable rocket engine turbopumps due to randomness in their cryogenic environment are investigated. The probabilistic simulation of the turbopumps' aerodynamic response was accomplished using the panel method coupled with Fast Probability Integration methods. The results are presented for the probabilistic rotor blades and splitter loading and their sensitivity to specified flow coefficient and rotor preswirl variance.

Hamed, Awatef↗

NASA NTRS1989

A combined Eulerian-Lagrangian two-phase analysis of the SSME HPOTP nozzle plug trajectories

As a result of high cycle fatigue, hydrogen embrittlement, and extended engine use, it was observed in testing that the trailing edge on the first stage nozzle plug in the High Pressure Oxygen Turbopump (HPOTP) could detach. The objective was to predict the trajectories followed by particles exiting the turbine. Experiments had shown that the heat exchanger soils, which lie downstream of the turbine, would be ruptured by particles traveling in the order of 360 ft/sec. An axisymmetric solution of the flow was obtained from the work of Lin et. al., who used INS3D to obtain the solution. The particle trajectories were obtained using the method of de Jong et. al., which employs Lagrangian tracking of the particle through the Eulerian flow field. The collision parameters were obtained from experiments conducted by Rocketdyne using problem specific alloys, speeds, and projectile geometries. A complete 3-D analysis using the most likely collision parameters shows maximum particle velocities of 200 ft/sec. in the heat exchanger region. Subsequent to this analysis, an engine level test was conducted in which seven particles passed through the turbine but no damage was observed on the heat exchanger coils.

Garcia, Robert↗