Effect of convergent ejector nozzles on the boattail drag of a 16 degree conical afterbody at Mach numbers of 0.6 to 1.26
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The research project reported herein extended over a period from October 1997 through August 1999. The research resulted in three technical papers presented at the AIAA/SAE/ASME/ASEE 35th Joint Propulsion Conference in Los Angeles in July 1999. These three papers are attached to this Executive Summary to constitute the final report. Objective: The objective of this research was to determine the mixing characteristics between the primary rocket jets and the turbine exhaust stream in a simulated Rocket Based Combined Cycle propulsion concept operating in the air augmented rocket mode.
The objectives of the initial effort (Phase I) of HSR Liner Technology Program, the selection of promising liner concepts, design and fabrication of these concepts for laboratory tests, testing these liners in the laboratory by using impedance tube and flow ducts, and developing empirical impedance/suppression correlation, are successfully completed. Acoustic and aerodynamic criteria for the liner design are established. Based on these criteria several liners are designed. The liner concepts designed and fabricated include Single-Degree-of-Freedom (SDOF), Two-Degree-of-Freedom (2DOF), and Bulk Absorber. Two types of SDOF treatment are fabricated, one with a perforated type face plate and the other with a wiremesh (woven) type faceplate. In addition, special configurations of these concepts are also included in the design. Several treatment panels are designed for parametric study. In these panels the facesheets of different porosity, hole diameter, and sheet thickness are utilized. Several deep panels (i.e., 1 in. deep) are designed and instrumented to measure DC flow resistance and insitu impedance in the presence of grazing flow. Basic components of these panels (i.e., facesheets, bulk materials, etc.) are also procured and tested. The results include DC flow resistance, normal impedance, and insertion loss.
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Due to the aft, upper surface engine location on the Hybrid Wing Body (HWB) planform, there is potential to shed vorticity and separated wakes into the engine when the vehicle is operated at off-design conditions and corners of the envelope required for engine and airplane certification. CFD simulations were performed of the full-scale reference propulsion system, operating at a range of inlet flow rates, flight speeds, altitudes, angles of attack, and angles of sideslip to identify the conditions which produce the largest distortion and lowest pressure recovery. Pretest CFD was performed by NASA and Boeing, using multiple CFD codes, with various turbulence models. These data were used to make decisions regarding model integration, characterize inlet flow distortion patterns, and help define the wind tunnel test matrix. CFD was also performed post-test; when compared with test data, it was possible to make comparisons between measured model-scale and predicted full-scale distortion levels. This paper summarizes these CFD analyses.
As part of the NASA Environmentally Responsible Aircraft project, an ultra high bypass ratio engine integration on a hybrid wing body demonstration was planned. The goal was to include engine and airframe integration concepts that reduced fuel consumption by at least 50% while still reducing noise 42 db cumulative on the ground. Since the engines would be mounted on the upper surface of the aft body of the aircraft, the inlets may be susceptible to vortex ingestion from the wing leading edge at high angles of attack and sideslip, and separated wing/body flow. Consequently, experimental and computational studies were conducted to collect flow surveys useful for characterizing engine operability. The wind tunnel tests were conducted at two NASA facilities, the 14- by 22-foot at NASA Langley and the 40- by 80-foot at NASA Ames Research Center. The test results included in this paper show that the distortion and pressure recovery levels were acceptable for engine operability. The CFD studies conducted to compare to experimental data showed excellent agreement for the angle of attacks examined, although failed to match the low speed experimental data at high sideslip angles.
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Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively. The Mach Number distribution shows small yet distinct differences between the two cases such as locations of shocks/shock reflections and a slightly different impingement point on the wall of the diffuser from the expansion at the exit of the nozzle. Similarly the temperature distribution indicates different flow recirculation patterns in the test cell. Both cases capture all the essential flow phenomena such as the shock-boundary layer interaction, plume expansion, expansion of the first stage ejectors, mixing between the engine plume and the first stage ejector flow and pressurization due to the first stage ejectors. The final paper will discuss thermal loads on the walls of the diffuser and cooling mechanisms investigated.
The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.
Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively.
Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Design Support of the feasibility of operating conditions and procedures is critical in such cases due to the possibility of startup/shutdown transients, moving shock structures, unsteady shock-boundary layer interactions and engine and diffuser unstart modes that can result in catastrophic failure. Analyses of such systems is difficult due to resolution requirements needed to accurately capture moving shock structures, shock-boundary layer interactions, two-phase flow regimes and engine unstart modes. In a companion paper, we will demonstrate with the use of CFD, steady analyses advanced capability to evaluate supersonic diffuser and steam ejector performance in the sub-scale A-3 facility. In this paper we will address transient issues with the operation of the facility especially at startup and shutdown, and assess risks related to afterburning due to the interaction of a fuel rich plume with oxygen that is a by-product of the steam ejectors. The primary areas that will be addressed in this paper are: (1) analyses of unstart modes due to flow transients especially during startup/ignition, (2) engine safety during the shutdown process (3) interaction of steam ejectors with the primary plume i.e. flow transients as well as probability of afterburning. In this abstract we discuss unsteady analyses of the engine shutdown process. However, the final paper will include analyses of a staged startup, drawdown of the engine test cell pressure, and risk assessment of potential afterburning in the facility. Unsteady simulations have been carried out to study the engine shutdown process in the facility and understand the physics behind the interactions between the steam ejectors, the test cell and the supersonic diffuser. As a first approximation, to understand the dominant unsteady mechanisms in the engine test cell and the supersonic diffuser, the turning duct in the facility was removed. As the engine loses power a rarefaction wave travels downstream that disrupts the shock cell structure in the supersonic diffuser. Flow from the test cell is seen to expand into the supersonic diffuser section and re-pressurizes the area around the nozzle along with a upstream traveling compression wave that emanates from near the first stage ejectors. Flow from the first stage ejector expands to the center of the duct and a new shock train is formed between the first and second stage ejectors. Both stage ejectors keep the facility pressurized and prevent any large amplitude pressure fluctuations from affecting the engine nozzle. The resultant pressure loads the nozzle experiences in the shutdown process are small.
A fluid channeling system includes a fluid ejector, a heat exchanger, and a fluid pump disposed in series flow communication The ejector includes a primary inlet for receiving a primary fluid, and a secondary inlet for receiving a secondary fluid which is mixed with the primary fluid and discharged therefrom as ejector discharge. Heat is removed from the ejector discharge in the heat exchanger, and the heat exchanger discharge is compressed in the fluid pump and channeled to the ejector secondary inlet as the secondary fluid In an exemplary embodiment, the temperature of the primary fluid is greater than the maximum operating temperature of a fluid motor powering the fluid pump using a portion of the ejector discharge, with the secondary fluid being mixed with the primary fluid so that the ejector discharge temperature is equal to about the maximum operating temperature of the fluid motor.
The topics covered include the following: 20 dB jet noise suppression; ejector nozzle technology program - noise reduction vs. flow augmentation; mixer ejector nozzle technology challenges; 1989 High Speed Civil Transport (HSCT) 2-D ejector model test in NASA's 9 x 15 ft. tunnel; tertiary airflow 1989 2-D ejector test; shock noise dominates 2-D ejector test; lessons learned - 2-D mixer/ejector in 9 x 15 ft. tunnel; 1990 HSCT axisymmetric ejector model test in Boeing's Low Speed Aeroacoustic Facility (LSAF); axisymmetric mixer/ejector mach contours - peak and valley - NASTAR pre-test predictions; tertiary airflow objectives accomplished - 1990 AXI model; and HSCT low noise exhaust technology programs.
The all rocket mode of operation is shown to be a critical factor in the overall performance of a rocket based combined cycle (RBCC) vehicle. An axisymmetric RBCC engine was used to determine specific impulse efficiency values based upon both full flow and gas generator configurations. Design of experiments methodology was used to construct a test matrix and multiple linear regression analysis was used to build parametric models. The main parameters investigated in this study were: rocket chamber pressure, rocket exit area ratio, injected secondary flow, mixer-ejector inlet area, mixer-ejector area ratio, and mixer-ejector length-to-inlet diameter ratio. A perfect gas computational fluid dynamics analysis, using both the Spalart-Allmaras and k-omega turbulence models, was performed with the NPARC code to obtain values of vacuum specific impulse. Results from the multiple linear regression analysis showed that for both the full flow and gas generator configurations increasing mixer-ejector area ratio and rocket area ratio increase performance, while increasing mixer-ejector inlet area ratio and mixer-ejector length-to-diameter ratio decrease performance. Increasing injected secondary flow increased performance for the gas generator analysis, but was not statistically significant for the full flow analysis. Chamber pressure was found to be not statistically significant.
The theory of mixer-ejectors for noise suppression is illustrated in this cartoon. Since jet noise SPL scales as velocity to the eighth power and diameter squared, increasing the jet diameter while lowering its velocity and keeping thrust constant decreases the noise. However, in supersonic craft, the drag penalty for increasing diameter at supersonic cruise makes this option very expensive. One would like to have a large engine during takeoff which could be shrunk during cruise. The retractable ejector is such an expandable engine. If the mixer flow can be expanded to the size of the ejector exit, the noise generated downstream of the ejector will be much less than the small diameter mixer nozzle alone. Of course, this also requires that the noise created in expanding the flow to fill the ejector be absorbed by a liner in the ejector walls so that none of this noise is heard. Since this mixing of internal hot gas and external cold air must take place in as short a distance as possible, the mixer must be very effective and therefore probably much noisier than a simple nozzle.
The principle objectives of the current program were to experimentally investigate the repeatability of acoustic and aerodynamic characteristics of 2D-CD mixer-ejector nozzles and the effects on the acoustic and aerodynamic characteristics of 2D mixer-ejectors due to (1) the configurational variations, which include mixers with aligned CD chutes, aligned convergent chutes, and staggered CD chutes and aerodynamic cycle variables, (2) treatment variations by using different treatment materials, treating the ejector with varying area, location, and treatment thickness for a mixer-ejector configuration, and (3) secondary inlet shape (i.e., a more realistic inlet) and the blockage across the inlet (a possible fin-like structure needed for installation purpose) by modifying one of the inlet of a mixer-ejector configuration. The objectives also included the measurement dynamic pressures internal to the ejector for a few selected configuration to examine the internal noise characteristics.