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NASA NTRS1997

Static Investigation of a Multiaxis Thrust-Vectoring Nozzle With Variable Internal Contouring Ability

The thrust efficiency and vectoring performance of a convergent-divergent nozzle were investigated at static conditions in the model preparation area of the Langley 16-Foot Transonic Tunnel. The diamond-shaped nozzle was capable of varying the internal contour of each quadrant individually by using cam mechanisms and retractable drawers to produce pitch and yaw thrust vectoring. Pitch thrust vectoring was achieved by either retracting the lower drawers to incline the throat or varying the internal flow-path contours to incline the throat. Yaw thrust vectoring was achieved by reducing flow area left of the nozzle centerline and increasing flow area right of the nozzle centerline; a skewed throat deflected the flow in the lateral direction.

Wing, David J.↗

NASA NTRS1997

Flight-Determined Subsonic Longitudinal Stability and Control Derivatives of the F-18 High Angle of Attack Research Vehicle (HARV) with Thrust Vectoring

The subsonic longitudinal stability and control derivatives of the F-18 High Angle of Attack Research Vehicle (HARV) are extracted from dynamic flight data using a maximum likelihood parameter identification technique. The technique uses the linearized aircraft equations of motion in their continuous/discrete form and accounts for state and measurement noise as well as thrust-vectoring effects. State noise is used to model the uncommanded forcing function caused by unsteady aerodynamics over the aircraft, particularly at high angles of attack. Thrust vectoring was implemented using electrohydraulically-actuated nozzle postexit vanes and a specialized research flight control system. During maneuvers, a control system feature provided independent aerodynamic control surface inputs and independent thrust-vectoring vane inputs, thereby eliminating correlations between the aircraft states and controls. Substantial variations in control excitation and dynamic response were exhibited for maneuvers conducted at different angles of attack. Opposing vane interactions caused most thrust-vectoring inputs to experience some exhaust plume interference and thus reduced effectiveness. The estimated stability and control derivatives are plotted, and a discussion relates them to predicted values and maneuver quality.

Iliff, Kenneth W.↗

NASA NTRS1959

Flight Measurements of the Effect of a Controllable Thrust Reverser on the Flight Characteristics of a Single-Engine Jet Airplane

A flight investigation was undertaken to determine the effect of a fully controllable thrust reverser on the flight characteristics of a single-engine jet airplane. Tests were made using a cylindrical target-type reverser actuated by a hydraulic cylinder through a "beep-type" cockpit control mounted at the base of the throttle. The thrust reverser was evaluated as an in-flight decelerating device, as a flight path control and airspeed control in landing approach, and as a braking device during the ground roll. Full deflection of the reverser for one reverser configuration resulted in a reverse thrust ratio of as much as 85 percent, which at maximum engine power corresponded to a reversed thrust of 5100 pounds. Use of the reverser in landing approach made possible a wide selection of approach angles, a large reduction in approach speed at steep approach angles, improved control of flight path angle, and more accuracy in hitting a given touchdown point. The use of the reverser as a speed brake at lower airspeeds was compromised by a longitudinal trim change. At the lower airspeeds and higher engine powers there was insufficient elevator power to overcome the nose-down trim change at full reverser deflection.

Anderson, Seth B.↗

NASA NTRS1998

A Method for Integrating Thrust-Vectoring and Actuated Forebody Strakes with Conventional Aerodynamic Controls on a High-Performance Fighter Airplane

A method, called pseudo controls, of integrating several airplane controls to achieve cooperative operation is presented. The method eliminates conflicting control motions, minimizes the number of feedback control gains, and reduces the complication of feedback gain schedules. The method is applied to the lateral/directional controls of a modified high-performance airplane. The airplane has a conventional set of aerodynamic controls, an experimental set of thrust-vectoring controls, and an experimental set of actuated forebody strakes. The experimental controls give the airplane additional control power for enhanced stability and maneuvering capabilities while flying over an expanded envelope, especially at high angles of attack. The flight controls are scheduled to generate independent body-axis control moments. These control moments are coordinated to produce stability-axis angular accelerations. Inertial coupling moments are compensated. Thrust-vectoring controls are engaged according to their effectiveness relative to that of the aerodynamic controls. Vane-relief logic removes steady and slowly varying commands from the thrust-vectoring controls to alleviate heating of the thrust turning devices. The actuated forebody strakes are engaged at high angles of attack. This report presents the forward-loop elements of a flight control system that positions the flight controls according to the desired stability-axis accelerations. This report does not include the generation of the required angular acceleration commands by means of pilot controls or the feedback of sensed airplane motions.

Lallman, Frederick J.↗

NASA NTRS2000

Lightweight Chambers for Thrust Cell Applications

Traditional metals like steel and copper alloys have been used for many years to fabricate injector and chamber components of thruster assemblies. While the materials perform well, reducing engine weights would help existing and future vehicles gain performance and payload capability. It may now be possible to reduce current thruster weights up to 50% by applying composite materials. In this task, these materials are being applied to an existing thrust cell design to demonstrate new fabrication processes and potential weight savings. Two ceramic matrix composite (CMC) designs, three polymer matrix composite (PMC) designs, and two metal matrix composite (MMC) designs are being fabricated as small chamber demonstration units. In addition, a new alloy of copper, chrome, and niobium (Cu-8Cr-4Nb) is being investigated for thrust chamber liners since it offers higher strength and increased cycle life over traditional alloys. This new alloy is being used for the liner in each MMC and PMC demonstration unit. During June-August of 2000, hot-fire testing of each unit is planned to validate designs in an oxygen/hydrogen environment at chamber pressures around 850 psi. Although the weight savings using CMC materials is expected to be high, they have proven to be much harder to incorporate into chamber designs based on current fabrication efforts. However, the PMC & MMC concepts using the Cu-8Cr-4Nb liner are nearly complete and ready for testing. Additional efforts intend to use the PMC & MMC materials to fabricate a full size thrust chamber (60K lb(sub f) thrust class). The fabrication of this full size unit is expected to be complete by October 2000, followed by hot-fire testing in November-December 2000.

Elam, S.↗

NASA NTRS2000

Computational Investigation of the Aerodynamic Effects on Fluidic Thrust Vectoring

A computational investigation of the aerodynamic effects on fluidic thrust vectoring has been conducted. Three-dimensional simulations of a two-dimensional, convergent-divergent (2DCD) nozzle with fluidic injection for pitch vector control were run with the computational fluid dynamics code PAB using turbulence closure and linear Reynolds stress modeling. Simulations were computed with static freestream conditions (M=0.05) and at Mach numbers from M=0.3 to 1.2, with scheduled nozzle pressure ratios (from 3.6 to 7.2) and secondary to primary total pressure ratios of p(sub t,s)/p(sub t,p)=0.6 and 1.0. Results indicate that the freestream flow decreases vectoring performance and thrust efficiency compared with static (wind-off) conditions. The aerodynamic penalty to thrust vector angle ranged from 1.5 degrees at a nozzle pressure ratio of 6 with M=0.9 freestream conditions to 2.9 degrees at a nozzle pressure ratio of 5.2 with M=0.7 freestream conditions, compared to the same nozzle pressure ratios with static freestream conditions. The aerodynamic penalty to thrust ratio decreased from 4 percent to 0.8 percent as nozzle pressure ratio increased from 3.6 to 7.2. As expected, the freestream flow had little influence on discharge coefficient.

Deere, K. A.↗

NASA NTRS2000

A Regeneratively Cooled Thrust Chamber For The Fastrac Engine

Abstract This paper presents the development of a low-cost, regeneratively-cooled thrust chamber for the Fastrac engine. The chamber was fabricated using hydraformed copper tubing to form the coolant jacket and wrapped with a fiber reinforced polymer composite Material to form a structural jacket. The thrust chamber design and fabrication approach was based upon Space America. Inc.'s 12,000 lb regeneratively-cooled LOX/kerosene rocket engine. Fabrication of regeneratively cooled thrust chambers by tubewall construction dates back to the early US ballistic missile programs. The most significant innovations in this design was the development of a low-cost process for fabrication from copper tubing (nickel alloy was the usual practice) and use of graphite composite overwrap as the pressure containment, which yields an easily fabricated, lightweight pressure jacket around the copper tubes A regeneratively-cooled reusable thrust chamber can benefit the Fastrac engine program by allowing more efficient (cost and scheduler testing). A proof-of-concept test article has been fabricated and will he tested at Marshall Space Flight Center in the late Summer or Fall of 2000.

Brown, Kendall K.↗

NASA NTRS2001

Lightweight Chambers for Thrust Assemblies

The Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) has successfully applied new materials and fabrication techniques to create actively cooled thrust chambers that operate 200-400 degrees hotter and weigh 50% lighter than conventional designs. In some vehicles, thrust assemblies account for as much as 20% of the engine weight. So, reducing the weight of these components and increasing their operating range will benefit many engines and vehicle designs, including Reusable Launch Vehicle (RLV) concepts. Obviously, copper and steel alloys have been used successfully for many years in the chamber components of thrust assemblies. Yet, by replacing the steel alloys with Polymer Matrix Composite (PMC) and/or Metal Matrix Composite (MMC) materials, design weights can be drastically reduced. In addition, replacing the traditional copper alloys with a Ceramic Matrix Composite (CMC) or an advanced copper alloy (Cu-8Cr-4Nb, also known as GRCop-84) significantly increases allowable operating temperatures. Several small MMC and PMC demonstration chambers have recently been fabricated with promising results. Each of these designs included GRCop-84 for the cooled chamber liner. These units successfully verified that designs over 50% lighter are feasible. New fabrication processes, including advanced casting technology and a low cost vacuum plasma spray (VPS) process, were also demonstrated with these units. Hot-fire testing at MSFC is currently being conducted on the chambers to verify increased operating temperatures available with the GRCop-84 liner. Unique CMC chamber liners were also successfully fabricated and prepared for hot-fire testing. Yet, early results indicate these CMC liners need significantly more development in order to use them in required chamber designs. Based on the successful efforts with the MMC and PMC concepts, two full size "lightweight" chambers are currently being designed and fabricated for hot-fire testing at MSFC in 2001. These "full size" chambers will be similar in size to those used on the X33 engine (RS2200). One will be fabricated with a MMC structural jacket, while the other uses a PMC jacket. Each will be designed for thrust levels of 15,000 pounds in an oxygen/hydrogen environment with liquid hydrogen coolant. Both chambers will use GRCop-84 for its channel wall liner. Each unit is expected to be at least 60% lighter than a conventional design with traditional materials. Hot-fire testing on the full size units in late 2001 will directly compare performance results between a conventional chamber design and these "lightweight" alternatives. The technology developed and demonstrated by this effort will not only benefit next generation RLV programs, but it can be applied to other existing and future engine programs, as well. Efforts were sponsored by the Advanced Space Transportation Program for RLV Focused Technologies. The task team was led by MSFC with additional members from NASA-Glenn Research Center and the Rocketdyne Division of The Boeing Company. Specific materials development and fabrication processes were provided by Aerojet, Lockheed Martin Astronautics, Composite Optics, Inc., Hyper-Therm, Ceramic Composites, Inc., MSE Technology Applications, and Plasma Processes, Inc.

Elam, Sandra K.↗

NASA NTRS2000

Development of an Integrated Rocket Thrust Chamber Assembly Analysis and Design Toolkit (TCAT)

There are many individual computational tools and methods used to analyze and design components of a rocket engine thrust chamber assembly (TCA) 11,21. To analyze and design a thrust chamber assembly these tools are usually used in sequence while communication of information between these tools is usually done manually. Each component of a TCA is usually designed and optimized individually with limited considerations on system optimized design. This approach is often iterative and can be prone to error. Also at present, expert knowledge of each tool is required. The objective of this software development effort is to select, integrate and automate the best tools into an easy-to-use computational package, the Thrust Chamber Analysis Toolkit (TCAT). This tool will provide a seamless process to analyze and design all or individual components of a thrust chamber assembly. This paper describes the current status of the MAT software development. The selected component codes and their capabilities are briefly described. User and module interfaces and integration status are presented. MAT pre- and post-processing added options are presented and overall MAT capabilities are demonstrated with the results of sample cases. Ongoing and planned model validation efforts are also described. Finally, the MAT future plan options are discussed.

Farhangi, S.↗

NASA NTRS2002

A Method of Efficient Inclination Changes for Low-thrust Spacecraft

The evolution of low-thrust propulsion technologies has reached a point where such systems have become an economical option for many space missions. The development of efficient, low trip time control laws has received an increasing amount of attention in recent years, though few studies have examined the subject of inclination changing maneuvers in detail. A method for performing economical inclination changes through the use of an efficiency factor is derived front Lagrange's planetary equations. The efficiency factor can be used to regulate propellant expenditure at the expense of trip time. Such a method can be used for discontinuous-thrust transfers that offer reduced propellant masses and trip-times in comparison to continuous thrust transfers, while utilizing thrusters that operate at a lower specific impulse. Performance comparisons of transfers utilizing this approach with continuous-thrust transfers are generated through trajectory simulation and are presented in this paper.

Falck, Robert↗

NASA NTRS2003

Experimental and Computational Investigation of Multiple Injection Ports in a Convergent-Divergent Nozzle for Fluidic Thrust Vectoring

A computational and experimental study was conducted to investigate the effects of multiple injection ports in a two-dimensional, convergent-divergent nozzle, for fluidic thrust vectoring. The concept of multiple injection ports was conceived to enhance the thrust vectoring capability of a convergent-divergent nozzle over that of a single injection port without increasing the secondary mass flow rate requirements. The experimental study was conducted at static conditions in the Jet Exit Test Facility of the 16-Foot Transonic Tunnel Complex at NASA Langley Research Center. Internal nozzle performance was obtained at nozzle pressure ratios up to 10 with secondary nozzle pressure ratios up to 1 for five configurations. The computational study was conducted using the Reynolds Averaged Navier-Stokes computational fluid dynamics code PAB3D with two-equation turbulence closure and linear Reynolds stress modeling. Internal nozzle performance was predicted for nozzle pressure ratios up to 10 with a secondary nozzle pressure ratio of 0.7 for two configurations. Results from the experimental study indicate a benefit to multiple injection ports in a convergent-divergent nozzle. In general, increasing the number of injection ports from one to two increased the pitch thrust vectoring capability without any thrust performance penalties at nozzle pressure ratios less than 4 with high secondary pressure ratios. Results from the computational study are in excellent agreement with experimental results and validates PAB3D as a tool for predicting internal nozzle performance of a two dimensional, convergent-divergent nozzle with multiple injection ports.

Waithe, Kenrick A.↗

NASA NTRS2003

Summary of Fluidic Thrust Vectoring Research Conducted at NASA Langley Research Center

Interest in low-observable aircraft and in lowering an aircraft's exhaust system weight sparked decades of research for fixed geometry exhaust nozzles. The desire for such integrated exhaust nozzles was the catalyst for new fluidic control techniques; including throat area control, expansion control, and thrust-vector angle control. This paper summarizes a variety of fluidic thrust vectoring concepts that have been tested both experimentally and computationally at NASA Langley Research Center. The nozzle concepts are divided into three categories according to the method used for fluidic thrust vectoring: the shock vector control method, the throat shifting method, and the counterflow method. This paper explains the thrust vectoring mechanism for each fluidic method, provides examples of configurations tested for each method, and discusses the advantages and disadvantages of each method.

Deere, Karen A.↗

NASA NTRS2003

Experimental and Computational Investigation of Multiple Injection Ports in a Convergent-Divergent Nozzle for Fluidic Thrust Vectoring

Waithe, Kenrick A.↗

NASA NTRS1961

Large-Scale Wind-Tunnel Tests of Exhaust Ingestion Due to Thrust Reversal on a Four-Engine Jet Transport during Ground Roll

Wind-tunnel tests have been conducted on a large-scale model of a swept-wing jet transport type airplane to study the factors affecting exhaust gas ingestion into the engine inlets when thrust reversal is used during ground roll. The model was equipped with four small jet engines mounted in nacelles beneath the wing. The tests included studies of both cascade and target type reversers. The data obtained included the free-stream velocity at the occurrence of exhaust gas ingestion in the outboard engine and the increment of drag due to thrust reversal for various modifications of thrust reverser configuration. Motion picture films of smoke flow studies were also obtained to supplement the data. The results show that the free-stream velocity at which ingestion occurred in the outboard engines could be reduced considerably, by simple modifications to the reversers, without reducing the effective drag due to reversed thrust.

Tolhurst, William H., Jr.↗

NASA NTRS1952

Preliminary Air-Flow and Thrust Calibrations of Several Conical Cooling-Air Ejectors with a Primary to Secondary Temperature Ratio of 1.0: Diameter Ratios of 1.06 and 1.40 - 2

An investigation was made of the performance of nine conical cooling-air ejectors at primary jet pressure ratios from 1 to 10, secondary pressure ratios to 4.0, and a temperature ratio of unity. This phase of the investigation was limited to conical ejectors having shroud exit to primary nozzle exit diameter ratios of 1.06 and 1.40, with several spacing ratios for each. The experimental results indicated that the pumping range and amount of cooling-air flow obtained with a 1.06 diameter ratio ejector were relatively small for cooling purposes but that the maximum possible thrust loss, which occurred with no secondary flow, was only 7 percent of convergent nozzle thrust. The 1.40 diameter ratio ejector produced a large cooling air flow and showed a possible thrust loss of 29.5 percent with no cooling air flow. Thrust gains were attained with ejectors of both diameter ratios at secondary pressure ratios greater than 1.0. The limiting primary pressure ratio below which an ejector can operate at a specific secondary pressure ratio (cut-off point) may be estimated for various flight conditions from data contained herein.

Greathouse, W. K.↗

NASA NTRS2004

Analysis of Factors Affecting the Performance of RLV Thrust Cell Liners

The reusable launch vehicle (RLV) thrust cell liner, or thrust chamber, is a critical component of the Space Shuttle Main Engine (SSME). It is designed to operate in some of the most severe conditions seen in engineering practice. This requirement, in conjunction with experimentally observed 'dog-house' failure modes characterized by bulging and thinning of the cooling channel wall, provides the motivation to study the factors that influence RLV thrust cell liner performance. Factors or parameters believed to be directly related to the observed characteristic deformation modes leading to failure under in-service loading conditions are identified, and subsequently investigated using the cylindrical version of the higher-order theory for functionally graded materials in conjunction with the Robinson's unified viscoplasticity theory and the power-law creep model for modeling the response of the liner s constituents. Configurations are analyzed in which specific modifications in cooling channel wall thickness or constituent materials are made to determine the influence of these parameters on the deformations resulting in the observed failure modes in the outer walls of the cooling channel. The application of thermal barrier coatings and functional grading are also investigated within this context. Comparison of the higher-order theory results based on the Robinson and power-law creep model predictions has demonstrated that, using the available material parameters, the power-law creep model predicts more precisely the experimentally observed deformation leading to the 'dog-house' failure mode for multiple short cycles, while also providing much improved computational efficiency. However, for a single long cycle, both models predict virtually identical deformations. Increasing the power-law creep model coefficients produces appreciable deformations after just one long cycle that would normally be obtained after multiple cycles, thereby enhancing the efficiency of the analysis. This provides a basis for the development of an accelerated modeling procedure to further characterize dog-house deformation modes in RLV thrust cell liners. Additionally, the results presented herein have demonstrated that the mechanism responsible for deformation leading to 'dog-house' failure modes is driven by pressure, creep/relaxation and geometric effects.

Arnold, Steven M.↗

NASA NTRS1997

Fluidic Thrust Vectoring of an Axisymmetric Exhaust Nozzle at Static Conditions

A sub-scale experimental static investigation of an axisymmetric nozzle with fluidic injection for thrust vectoring was conducted at the NASA Langley Jet Exit Test Facility. Fluidic injection was introduced through flush-mounted injection ports in the divergent section. Geometric variables included injection-port geometry and location. Test conditions included a range of nozzle pressure ratios from 2 to 10 and a range of injection total pressure ratio from no-flow to 1.5. The results indicate that fluidic injection in an axisymmetric nozzle operating at design conditions produced significant thrust-vector angles with less reduction in thrust efficiency than that of a fluidically-vectored rectangular jet. The axisymmetric geometry promoted a pressure relief mechanism around the injection slot, thereby reducing the strength of the oblique shock and the losses associated with it. Injection port geometry had minimal effect on thrust vectoring.

Wing, David J.↗

NASA NTRS2005

An Oil-Free Thrust Foil Bearing Facility Design, Calibration, and Operation

New testing capabilities are needed in order to foster thrust foil air bearing technology development and aid its transition into future Oil-Free gas turbines. This paper describes a new test apparatus capable of testing thrust foil air bearings up to 100 mm in diameter at speeds to 80,000 rpm and temperatures to 650 C (1200 F). Measured parameters include bearing torque, load capacity, and bearing temperatures. This data will be used for design performance evaluations and for validation of foil bearing models. Preliminary test results demonstrate that the rig is capable of testing thrust foil air bearings under a wide range of conditions which are anticipated in future Oil-Free gas turbines. Torque as a function of speed and temperature corroborates results expected from rudimentary performance models. A number of bearings were intentionally failed with no resultant damage whatsoever to the test rig. Several test conditions (specific speeds and loads) revealed undesirable axial shaft vibrations which have been attributed to the magnetic bearing control system and are under study. Based upon these preliminary results, this test rig will be a valuable tool for thrust foil bearing research, parametric studies and technology development.

Bauman, Steve↗