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Mechanical property evaluation, and functional tests of thermal insulation for liquid hydrogen tank of nuclear engine for rocket vehicle
Accurate modeling of liquid rocket engine test processes involves assessing critical fluid mechanic and heat and mass transfer mechanisms within a cryogenic environment, and accurately modeling fluid properties such as vapor pressure and liquid and gas densities as a function of pressure and temperature. The Engineering and Science Directorate at the NASA John C. Stennis Space Center has developed and implemented such analytic models and analysis processes that have been used over a broad range of thermodynamic systems and resulted in substantial improvements in rocket propulsion testing services. In this paper, we offer an overview of the analyses techniques used to simulate pressurization and propellant fluid systems associated with the test stands at the NASA John C. Stennis Space Center. More specifically, examples of the global performance (one-dimensional) of a propellant system are provided as predicted using the Rocket Propulsion Test Analysis (RPTA) model. Computational fluid dynamic (CFD) analyses utilizing multi-element, unstructured, moving grid capability of complex cryogenic feed ducts, transient valve operation, and pressurization and mixing in propellant tanks are provided as well.
A 60,000 lb trust liquid Oxygen (LOX) and rocket propellant #1 (RP-1) rocket engine is being developed at the Marshall Space Flight Center (MSFC) as part of NASA's ongoing effort to lower the cost of access to space. The goal of the program is to demonstrate a low cost rocket engine with acceptable performance. In order to reduce design and development risk, computational fluid dynamics (CFD) analysis was used extensively in the design process, especially in the design of the turbopump. This paper documents the process used and significant results obtained during the design of the LOX and RP-1 pumps. This includes the design of the inlet manifolds, the integral inducer-impellers, the diffusers, and the collector volutes. The resulting designs incorporate low-cost design features while meeting the engine cycle requirements.
Tests were conducted with the RS18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA s Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propellant systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to approx.120,000 ft (approx.37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. Propellant flow rate was measured using a coriolis-style mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup. LO2 flow ranged from 5.9-9.5 lbm/sec (2.7-4.3 kg/sec), and LCH4 flow varied from 3.0-4.4 lbm/sec (1.4-2.0 kg/sec) during the RS-18 hot-fire test series. Thrust was measured using three load cells in parallel. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Data was obtained at multiple chamber pressures, and calculations were performed for specific impulse, C* combustion efficiency, and thrust vector alignment. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes.
Tests were conducted with the RS-18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA's Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to ~122,000 ft (~37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. LO2 flow ranged from 5.9 - 9.5 lbm/sec (2.7 - 4.3 kg/sec), and LCH4 flow varied from 3.0 - 4.4 lbm/sec (1.4 - 2.0 kg/sec) during the RS-18 hot-fire test series. Propellant flow rate was measured using a coriolis mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup due to two-phase flow effects. Subsequent cold-flow testing demonstrated that the propellant manifolds must be adequately flushed in order for the coriolis flow meters to give accurate data. The coriolis flow meters were later shown to provide accurate steady-state data, but the turbine flow meter data should be used in transient phases of operation. Thrust was measured using three load cells in parallel, which also provides the capability to calculate thrust vector alignment. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes. All of these objectives were met with the RS-18 data and additional testing data from subsequent LO2/methane test programs in 2009 which included the first simulated-altitude pyrotechnic ignition demonstration of LO2/methane.
NASA Stennis Space Center's (SSC's) large rocket engine test facility requires the use of liquid propellants, including the use of cryogenic fluids like liquid hydrogen as fuel, and liquid oxygen as an oxidizer (gases which have been liquefied at very low temperatures). These fluids require special handling, storage, and transfer technology. The biggest problem associated with transferring cryogenic liquids is product loss due to heat transfer. Vacuum jacketed piping is specifically designed to maintain high thermal efficiency so that cryogenic liquids can be transferred with minimal heat transfer. A vacuum jacketed pipe is essentially two pipes in one. There is an inner carrier pipe, in which the cryogenic liquid is actually transferred, and an outer jacket pipe that supports and seals the vacuum insulation, forming the "vacuum jacket." The integrity of the vacuum jacketed transmission lines that transfer the cryogenic fluid from delivery barges to the test stand must be maintained prior to and during engine testing. To monitor the vacuum in these vacuum jacketed transmission lines, vacuum gauge readings are used. At SSC, vacuum gauge measurements are done on a manual rotation basis with two technicians, each using a handheld instrument. Manual collection of vacuum data is labor intensive and uses valuable personnel time. Additionally, there are times when personnel cannot collect the data in a timely fashion (i.e., when a leak is detected, measurements must be taken more often). Additionally, distribution of this data to all interested parties can be cumbersome. To simplify the vacuum-gauge data collection process, automate the data collection, and decrease the labor costs associated with acquiring these measurements, an automated system that monitors the existing gauges was developed by Invocon, Inc. For this project, Invocon developed a Wireless Integrated Microelectronic Vacuum Sensor System (WIMVSS) that provides the ability to gather vacuum-gauge measurements automatically and wirelessly, in near-real time - using a low-maintenance, lowpower sensor mesh network. The WIMVSS operates by using a self-configuring mesh network of wireless sensor units. Mesh networking is a type of networking where each sensor or node can capture and disseminate its own data, but also serve as a relay to receive and transmit data from other sensors. Each sensor node can synchronize with adjacent sensors, and propagate data from one sensor to the next, until the destination is reached. In this case, the destination is a Network Interface Unit (NIU). The WIMVSS sensors are mounted on the existing vacuum gauges. Information gathered by the sensors is sent to the NIU. Because of the mesh networking, if a sensor cannot directly send the data to the NIU, it can be propagated through the network of sensors. The NIU requires antenna access to the sensor units, AC power, and an Ethernet connection. The NIU bridges the sensor network to a WIMVSS server via an Ethernet connection. The server is configured with a database, a Web server, and proprietary interface software that makes it possible for the vacuum measurements from vacuum jacketed fluid lines to be saved, retrieved, and then displayed from any Web-enabled PC that has access to the Internet. Authorized users can then simply access the data from any PC with Internet connection. Commands can also be sent directly from the Web interface for control and maintenance of the sensor network. The technology enabled by the WIMVSS decreases labor required for gathering vacuum measurements, increases access to vacuum data by making it available on any computer with access to the Internet, increases the frequency with which data points can be acquired for evaluating the system, and decreases the recurring cost of the sensors by using off-the-shelf components and integrating these with heritage vacuum gauges.
Analytical and experimental study of regenerative cooling for FLOX methane engine with bulk boiling methane
Cooldown of large-diameter liquid hydrogen and liquid oxygen propellant piping systems at M-1 engine test complex
The F-1 is the powerful engine, that hurdled the Saturn V launch vehicle from the Earth to the moon on July 16,1969. The force that lifted the rocket overcoming the gravitational force during the first stage of the flight was provided by a cluster of five F-1 rocket engines, each of them developing over 1.5 million pounds of thrust (MSFC-MAN-507). The F-1 Rocket engine used RP-1 (Rocket Propellant-1, commercially known as Kerosene), as fuel with lox (liquid Oxygen) as oxidizer. NASA terminated Saturn V activity and has focused on Space Shuttle since 1972. The interest in rocket system has been revived to meet the National Launch System (NLS) program and a directive from the President to return to the Moon and exploration of the space including Mars. The new program Space Launch Initiative (SLI) is directed to drastically reduce the cost of flight for payloads, and adopt a reusable launch vehicle (RLV). To achieve this goal it is essential to have the ability of lifting huge payloads into low earth orbit. Probably requiring powerful boosters as strap-ons to a core vehicle, as was done for the Saturn launch vehicle. The logic in favor of adopting Saturn system, a proven technology, to meet the SLI challenge is very strong. The F-1 engine was the largest and most powerful liquid rocket engine ever built, and had exceptional performance. This study reviews the failure modes of the F-1 engine and propellant system.
Cryogenic Tanks are pressurized by inert gas such as Helium or Nitrogen to maintain the required pressure of the propellant delivered to the turbo-pump of a liquid rocket engine. Thermo-fluid system simulation tools are used to analyze the pressurization process of a cryogenic tank. Most system level codes (GFSSP and ROCETS) use single node1 to represent ullage which is the gaseous space in the tank. Ullage space in a cryogenic tank is highly stratified because the entering inert gas is at ambient temperature whereas the liquid propellant is at a cryogenic temperature. A single node model does not account for the effect of temperature gradient in the ullage. High fidelity Navier-Stokes based CFD model of Tank Pressurization is not practical for running a long duration transient model with thousands and millions of nodes. A possible recourse is to construct a multi-node model with system level code that can account for ullage stratification.
This paper presents pertinent results and assessment of propellant feed system leak detection as applied to the Linear Aerospike SR-71 Experiment (LASRE) program flown at the NASA Dryden Flight Research Center, Edwards, California. The LASRE was a flight test of an aerospike rocket engine using liquid oxygen and high-pressure gaseous hydrogen as propellants. The flight safety of the crew and the experiment demanded proven technologies and techniques that could detect leaks and assess the integrity of hazardous propellant feed systems. Point source detection and systematic detection were used. Point source detection was adequate for catching gross leakage from components of the propellant feed systems, but insufficient for clearing LASRE to levels of acceptability. Systematic detection, which used high-resolution instrumentation to evaluate the health of the system within a closed volume, provided a better means for assessing leak hazards. Oxygen sensors detected a leak rate of approximately 0.04 cubic inches per second of liquid oxygen. Pressure sensor data revealed speculated cryogenic boiloff through the fittings of the oxygen system, but location of the source(s) was indeterminable. Ultimately, LASRE was cancelled because leak detection techniques were unable to verify that oxygen levels could be maintained below flammability limits.
Concern regarding the efficiency, stability and safety margins of bi-propellant combustion in rocket engines has prompted the investigation of many specific aspects of spray evaporation, ignition and combustion previously not studied. The phenomenology of bi- propellant spray evaporation, ignition and combustion in a highly turbulent environment at elevated pressure is discussed.
The research covered by this third annual progress report represents a continuation of our efforts devoted to the study of detonation waves in liquid-gas systems. The motivation for the work is associated with liquid propellant rocket motor combustion instability although certainly the studies are also applicable to internal combustion engines, jet propulsion engines, safety aspects of spilled liquid fuel, coal mine explosions, and weaponry. The research has been divided into 5 phases, although all of them are intimately related. For the most part these phases are briefly summarized and the reader is referred to other publications for a more complete treatment. The exception to this is where the material herein represents the only printed information available on the particular facet of the problem. Phase A has been primarily concerned with the breakup and ignition of fuel drops by shock waves. The experimental portion of this study as well as a theoretical treatment of the ignition behavior was completed in the past year. The research is now concentrating on the passage of a shock wave over a burning drop. Phase B has been devoted to the assessment of the approximate energy release pattern in two phase detonations insofar as they affect the significant overpressures observed.
The objective of this dissertation is to characterize augmented spark impinging (torch) igniters. Torch igniters inject propellants into a small prechamber where a spark igniter imparts the activation energy to initiate combustion. The flame stabilizes within the prechamber and exits into the main combustion chamber where it ignites the main flow directly or by mixing with a coaxial flow to create a secondary flame. The underlying phenomena that promote reliable ignition are multifaceted and required a broad scope of investigations. Initial efforts focused on spark discharges across an annular geometry. Gaseous propellent projects the electrical arc toward the prechamber, where the arc and the thermal energy is imparted to the surrounding fluid then meets with a combustible mixture. Discharges are parametrically examined against pressure, spark-gap size, and exciter types to emulate transient engine startup. The energy imparted to the flow, approximate velocity, and distance traveled by the exhaust plume are determined. Spark quenching (no energy deposition) and its effects on perceived versus actual measurements are shown. Results outline the prechamber target zone where a combustible mixture is necessary for ignition. Next, three-dimensional, time-accurate, and nonreacting computational fluid dynamics simulations assess effects of geometric and mass flow differences on the size, location, and composition of a combustible mixture. Fluid dynamic phenomena are elucidated. Correlations between nondimensional variables are found. Results are coupled with a conservation-law analysis to produce novel objective functions. Lastly, a full-scale, modular torch igniter is tested. Injector sizes, mixture ratios, and injector momentum ratios are systematically varied to map ignition probability and ignition delay. Results show the importance of local mixture ratios, provide injector momentum ratios guidelines, and demonstrate reliable ignition of core mixture ratios typically outside flammability limits. The deliverable of this project is not a torch igniter or derivative thereof. Instead, this dissertation produces novel objective-functions for igniter design. These equations are functions of variables that may be constrained by engine-level requirements, physics, and experimental results from this work. They provide a foundation for future igniter design and will minimize iterative processes from the design cycle for next-generation ignition hardware.
Flow separation which plays an important role in the design of a rocket engine nozzle is discussed. For a given ambient pressure, the condition of no flow separation limits the area ratio and, therefore, the vacuum performance. Avoidance of performance loss due to area ratio limitation requires a correct prediction of the flow separation conditions. To provide a better understanding of the flow separation process, the principal behavior of flow separation in a supersonic overexpanded rocket nozzle is described. The hot firing separation tests from various sources are summarized, and the applicability and accuracy of the measurements are described. A comparison of the different data points allows an evaluation of the parameters that affect flow separation. The pertinent flow separation predicting methods, which are divided into theoretical and empirical correlations, are summarized and the numerical results are compared with the experimental points.
Low frequency combustion instability, known as chugging, is consistently experienced during shutdown in the fuel and oxidizer preburners of the Space Shuttle Main Engines. Such problems always occur during the helium purge of the residual oxidizer from the preburner manifolds during the shutdown sequence. Possible causes and triggering mechanisms are analyzed and details in modeling the fuel preburner chug are presented. A linearized chugging model, based on the foundation of previous models, capable of predicting the chug occurrence is discussed and the predicted results are presented and compared to experimental work performed by NASA. Sensitivity parameters such as chamber pressure, fuel and oxidizer temperatures, and the effective bulk modulus of the liquid oxidizer are considered in analyzing the fuel preburner chug. The computer program CHUGTEST is utilized to generate the stability boundary for each sensitivity study and the region for stable operation is identified.
Rocket engines using liquid oxygen (LOX) and hydrocarbon fuel as the propellants are being given serious consideration for future launch vehicle propulsion. Normally, the fuel is used to regeneratively cool the combustion chamber. However, hydrocarbons such as RP-1 are limited in their cooling capability. Another possibility for the coolant is the liquid oxygen. Combustion chambers previously tested with LOX and RP-1 as propellants and LOX as the collant demonstrated the feasibility of using liquid oxygen as a coolant up to a chamber pressure of 13.8 MPa (2000 psia). However, there was concern as to the effect on the integrity of the chamber liner if oxygen leaks into the combustion zone through fatigue cracks that may develop between the cooling passages and the hot gas side wall. In order to study this effect, chambers were fabricated with slots machined upstream of the throat between the cooling passage wall and the hot gas side wall to simulate cracks. The chambers were tested at a nominal chamber pressure of 8.6 MPa (1247 psia) over a range of mixture ratios from 1.9 to 3.1 using liquid oxygen as the coolant. The results of the testing showed that the leaking LOX did not have a deleterious effect on the chambers in the region of the slots. However, there was unexplained melting in the throat region of both chambers, but not in line with the slots.
Rocket engines using liquid oxygen (LOX) and hydrocarbon fuel as the propellants are being given serious consideration for future launch vehicle propulsion. Normally, the fuel is used to regeneratively cool the combustion chamber. However, hydrocarbons such as RP-1 are limited in their cooling capability. Another possibility for the coolant is the liquid oxygen. Combustion chambers previously tested with LOX and RP-1 as propellants and LOX as the coolant demonstrated the feasibility of using liquid oxygen as a coolant up to a chamber pressure of 13.8 MPa (2000 psia). However, there was concern as to the effect on the integrity of the chamber liner if oxygen leaks into the combustion zone through fatigue cracks that may develop between the cooling passages and the hot gas side wall. In order to study this effect, chambers were fabricated with slots machined upstream of the throat between the cooling passage wall and the hot gas side wall to simulate cracks. The chambers were tested at a nominal chamber pressure of 8.6 MPa (1247 psia) over a range of mixture ratios from 1.9 to 3.1 using liquid oxygen as the coolant. The results of the testing showed that the leaking LOX did not have a deleterious effect on the chambers in the region of the slots. However, there was unexplained melting in the throat region of both chambers, but not in line with the slots.