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The feasibility of using foil bearings in future earth-to-orbit rocket engines is studied. A design parameter of a LOX pump of the SSME was selected as a prototype for this study. It was found that three-pad journal bearings and eight-pad thrust bearings met the operating requirements of the LOX turbopump.
A preferred Pratt & Whitney conceptual Nuclear Thermal Rocket Engine (NTRE) has been designed based on the fundamental NASA priorities of safety, reliability, cost, and performance. The basic philosophy underlying the design of the XNR2000 is the utilization of the most reliable form of ultrahigh temperature nuclear fuel and development of a core configuration which is optimized for uniform power distribution, operational flexibility, power maneuverability, weight, and robustness. The P&W NTRE system employs a fast spectrum, cermet fueled reactor configured in an expander cycle to ensure maximum operational safety. The cermet fuel form provides retention of fuel and fission products as well as high strength. A high level of confidence is provided by benchmark analysis and independent evaluations.
A study (Escher and Flornes, 1966) of aerospace propulsion systems for a fully reusable earth-to-orbit space transport application that was performed in 1965-67 is reviewed. The present review provides a detailed, subject-focused technical retrospective on a key subsystem element of the rocket-based combined-cycle (RBCC) class of aerospace propulsion systems. The RBCC concept is considered to be a leading candidate propulsion approach for either SSTO or two-stage-to-orbit space transportaion applications.
The B-2 facility is designed to hot fire rocket engines or upper stage launch vehicles with up to 890,000 N thrust, after environmental conditioning of the test article in a simulated thermal vaccum space environment. The facility can handle cryogenic fuels and oxidizers. A steam ejector system maintains vacuum around the test article and on the engine discharge during the test firing. Two high speed computer systems control the test, monitor critical parameters and record all of the desired data.
The space shuttle utilizes several rocket engine systems, all of which must function with a high degree of reliability for successful mission completion. The space shuttle main engine (SSME) is by far the most complex of the rocket engine systems and is designed to be reusable. The reusability of spacecraft systems introduces many problems related to testing, reliability, and logistics. Components must be assembled from parts inventories in a manner which will most effectively utilize the available parts. Assembly must be scheduled to efficiently utilize available assembly benches while still maintaining flight schedules. Assembled components must be assigned to as many contiguous flights as possible, to minimize component changes. Each component must undergo a rigorous testing program prior to flight. In addition, testing and assembly of flight engines and components must be done in conjunction with the assembly and testing of developmental engines and components. The development, testing, manufacture, and flight assignments of the engine fleet involves the satisfaction of many logistical and operational requirements, subject to many constraints. The purpose of the SSME Component Assembly and Life Management Expert System (CALMES) is to assist the engine assembly and scheduling process, and to insure that these activities utilize available resources as efficiently as possible.
A moveable valve for controlling flow of a pressurized working fluid was designed. This valve consists of a hollow, moveable floating piston pressed against a stationary solid seat, and can use the working fluid to seal the valve. This open/closed, novel valve is able to use metal-to-metal seats, without requiring seat sliding action; therefore there are no associated damaging effects. During use, existing standard high-pressure ball valve seats tend to become damaged during rotation of the ball. Additionally, forces acting on the ball and stem create large amounts of friction. The combination of these effects can lead to system failure. In an attempt to reduce damaging effects and seat failures, soft seats in the ball valve have been eliminated; however, the sliding action of the ball across the highly loaded seat still tends to scratch the seat, causing failure. Also, in order to operate, ball valves require the use of large actuators. Positioning the metal-to-metal seats requires more loading, which tends to increase the size of the required actuator, and can also lead to other failures in other areas such as the stem and bearing mechanisms, thus increasing cost and maintenance. This novel non-sliding seat surface valve allows metal-to-metal seats without the damaging effects that can lead to failure, and enables large seating forces without damaging the valve. Additionally, this valve design, even when used with large, high-pressure applications, does not require large conventional valve actuators and the valve stem itself is eliminated. Actuation is achieved with the use of a small, simple solenoid valve. This design also eliminates the need for many seals used with existing ball valve and globe valve designs, which commonly cause failure, too. This, coupled with the elimination of the valve stem and conventional valve actuator, improves valve reliability and seat life. Other mechanical liftoff seats have been designed; however, they have only resulted in increased cost, and incurred other reliability issues. With this novel design, the seat is lifted by simply removing the working fluid pressure that presses it against the seat and no external force is required. By eliminating variables associated with existing ball and globe configurations that can have damaging effects upon a valve, this novel design reduces downtime in rocket engine test schedules and maintenance costs.
There are many instances involving liquid/gas interfaces and their dynamics in the design of liquid engine powered rockets such as the Space Launch System (SLS). Some examples of these applications are: Propellant tank draining and slosh, subcritical condition injector analysis for gas generators, preburners and thrust chambers, water deluge mitigation for launch induced environments and even solid rocket motor liquid slag dynamics. Commercially available CFD programs simulating gas/liquid interfaces using the Volume of Fluid approach are currently limited in their parallel scalability. In 2010 for instance, an internal NASA/MSFC review of three commercial tools revealed that parallel scalability was seriously compromised at 8 cpus and no additional speedup was possible after 32 cpus. Other non-interface CFD applications at the time were demonstrating useful parallel scalability up to 4,096 processors or more. Based on this review, NASA/MSFC initiated an effort to implement a Volume of Fluid implementation within the unstructured mesh, pressure-based algorithm CFD program, Loci-STREAM. After verification was achieved by comparing results to the commercial CFD program CFD-Ace+, and validation by direct comparison with data, Loci-STREAM-VoF is now the production CFD tool for propellant slosh force and slosh damping rate simulations at NASA/MSFC. On these applications, good parallel scalability has been demonstrated for problems sizes of tens of millions of cells and thousands of cpu cores. Ongoing efforts are focused on the application of Loci-STREAM-VoF to predict the transient flow patterns of water on the SLS Mobile Launch Platform in order to support the phasing of water for launch environment mitigation so that vehicle determinantal effects are not realized.
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Metal additive manufacturing (AM) is changing how complex aerospace parts are being designed and manufactured for rocket engines and launch vehicles. NASA has been leading AM efforts since the late 2000’s to mature specialty alloys for AM, advance AM processes, develop standards and infuse AM into rocket engines and the commercial supply chain. There are many types of AM processes and alloys in-use and this presentation will provide an overview of how NASA is applying these for rocket engines and the potential opportunities for AM in the future.
This viewgraph representation provides an overview of research which develops a quasi one dimensional chemistry computational fluid dynamics code to study the effect of nozzle design on the performance of pulse detonation rocket engines (PDREs). Topics considered include: PDREs vs. steady-state rocket engines (SSREs), PDRE cycles, numerical models of idealized PDRE performance, thrust determination of PDRE, specific geometries, and nozzle design and geometry.
The report outlines work performed in support of the flowpath development for the DRACO engine program. The design process initiated to develop a hypersonic axisymmetric inlet for a Mach 6 rocket-based combined cycle (RBCC) engine is discussed. Various design parametrics were investigated, including design shock-on-lip Mach number, cone angle, throat Mach number, throat angle. length of distributed compression, and subsonic diffuser contours. Conceptual mechanical designs consistent with installation into the D-21 vehicle were developed. Additionally, program planning for an intensive inlet development program to support a Critical Design Review in three years was performed. This development program included both analytical and experimental elements and support for a flight-capable inlet mechanical design.
The primary propulsion system (PPS) for the Space Station Freedom is discussed in terms of salient design characteristics and key testing procedures. The rocket engine modules contain reboost and attitude control thrusters, and their designs are illustrated showing the mounting structures, thruster solenoid valves, and thrust chambers. The propellant tank assembly for storing gaseous N pressurant and hydrazine propellant is described as are the system avionics, thruster solenoid valves, and latching isolation valves. PPS testing conducted on the development systems includes the use of a propulsion-module development unit, a development test article, and system qualification testing. Specific test articles include functional heaters, mass/thermal simulated components, flight-quality structures, and software control operations.
Airbreathing/Rocket combined-cycle, and specifically rocket-based combined- cycle (RBCC), propulsion systems, typically employ an internal engine flow-path installed primary rocket subsystem. To achieve acceptably short mixing lengths in effecting the "air augmentation" process, a large rocket-exhaust/air interfacial mixing surface is needed. This leads, in some engine design concepts, to a "cluster" of small rocket units, suitably arrayed in the flowpath. To support an early (1964) subscale ground-test of a specific RBCC concept, such a 12-rocket cluster was developed by NASA's Marshall Space Flight Center (MSFC). The small primary rockets used in the cluster assembly were modified versions of an existing small kerosene/oxygen water-cooled rocket engine unit routinely tested at MSFC. Following individual thrust-chamber tests and overall subsystem qualification testing, the cluster assembly was installed at the U. S. Air Force's Arnold Engineering Development Center (AEDC) for RBCC systems testing. (The results of the special air-augmented rocket testing are not covered here.) While this project was eventually successfully completed, a number of hardware integration problems were met, leading to catastrophic thrust chamber failures. The principal "lessons learned" in conducting this early primary rocket subsystem experimental effort are documented here as a basic knowledge-base contribution for the benefit of today's RBCC research and development community.
Most TRW liquid bi-propellant rocket engines built over the past thirty-plus years have employed a central element coaxial pintle injector and have operated with liquid/liquid propellant injection. This injector is a patented design exclusive to TRW and has unique features that make the rocket engine combustion characteristics different from those of other types of injector engine designs. Its many benefits include excellent combustion performance, efficient deep throttling, adaptability to low cost manufacturing, and high reliability. Approximately 200 pintle injector engines of various sizes and operating on a variety of propellants have been flown without a single inflight failure. An especially important feature of the pintle injector engine is its apparent inherent combustion stability. In over thirty years of development, testing, and production, TRW has never experienced combustion instability in any of its pintle injector engine designs. This has been true of engines operating over a range of thrust from 5 to 250,000 lbs. on earth-storable hypergolic propellants and a large number of smaller engines operating on a variety of propellants (21 combinations) in long duration-firing, pulsing (down to 2 msec), and deep throttling (as much as 19:1) modes. Operating chamber pressures have ranged from 10 to 3,500 psia. This record is particularly impressive given that typical TRW design practice does not consider combustion instability as an issue and no pintle engine has ever employed stability-enhancing features, such as baffles or acoustically resonant chambers. In spite of this, TRW engines have operated stably in regimes not possible with other types of injectors. Various physical explanations and combustion process models for this favorable stability characteristic have been postulated. However, a definitive study that unequivocally establishes the important stabilizing mechanisms still remains to be conducted.
As the small satellite launch vehicle (SSLV) market grows and NASA continues to prepare for upcoming missions in the Artemis program, John C. Stennis Space Center’s (SSC) testing facilities must adapt to the increasing demand in liquid rocket engine testing. The Rocket Propulsion Test Design and Analysis Project for this rotation focused in both of this areas through two separate subprojects, the creation of a Private Rocket Engine Database and the automatization of the A1-Set Point Prediction Model. To identify the testing requirements of future Stennis Space Center (SSC) costumers, an excel spread sheet was commissioned as a database to collect technical and non-technical features of over one hundred privately developed liquid and hybrid rocket engine. Similarly, The A-1 Set Point Sheet Model is used to satisfy Aerojet Rocketdyne’s testing requirements of Net Positive Suction Pressure (NPSP) for the RS-25 staged combustion cycle engine. To expand the capabilities of this prediction model, a feed back loop was programmed to automate the search of setpoints using Excel Visual Basic for Applications (VBA).
Rocketdyne is pursuing the conceptual design and development of a Rocket Based Combined Cycle (RBCC) engine for booster and SSTO, advanced reusable space transportation ARTT systems under contract with NASA Marshall Space Flight Center. The Rocketdyne concept is fixed geometry integrated Rocket, Ram Scramjet which is Hydrogen fueled and uses Hydrogen regenerative cooling. Vision vehicle integration studies have determined that scramjet operation to Mach 12 has high payoff for low cost reusable space transportation. Rocketdyne is internally developing versions of the concept for other applications in high speed aircraft and missiles with Hydrocarbon fuel systems. Subscale engine ground testing is underway for all modes of operation from takeoff to Mach 8. High altitude Rocket only mode tests will be completed as part of the ground test program to validate high expansion ratio performance. A unique feature of the ground test series is the inclusion of dynamic trajectory simulation with real time Mach number, altitude, engine throttling, and RBCC mode changes in a specially modified freejet test facility at GASL. Preliminary cold flow Air Augmented Rocket mode test results and Short Combustor tests have met program goals and have been used to integrate all modes of operation in a single combustor design with a fixed geometry inlet for design confirmation tests. A water cooled subscale engine is being fabricated and installed for test beginning the last quarter of 1997.
Within the rocket engine industry, SSME turbomachines are the de facto standards of success with regard to meeting aggressive performance requirements under challenging operational environments. Over the Shuttle era, SSME has invested heavily in our national inducer impeller design infrastructure. While both low and high pressure turbopump failures/anomaly resolution efforts spurred some of these investments, the SSME program was a major benefactor of key areas of turbomachinery inducer-impeller research outside of flight manifest pressures. Over the past several decades, key turbopump internal environments have been interrogated via highly instrumented hot-fire and cold-flow testing. Likewise, SSME has sponsored the advancement of time accurate and cavitating inducer impeller computation fluid dynamics (CFD) tools. These investments together have led to a better understanding of the complex internal flow fields within aggressive high performing inducers and impellers. New design tools and methodologies have evolved which intend to provide confident blade designs which strike an appropriate balance between performance and self induced load management.
Several current rocket engine concepts such as the bell-annular tri-propellant engine, and the linear aerospike being proposed for the X-33 require unconventional three dimensional rocket nozzles which must conform to rectangular or sector shaped envelopes to meet integration constraints. These types of nozzles exist outside the current experience database, therefore, the application of efficient design methods for these propulsion concepts is critical to the success of launch vehicle programs. The objective of this work is to optimize several different nozzle configurations, including two- and three-dimensional geometries. Methodology includes coupling computational fluid dynamic (CFD) analysis to genetic algorithms and Taguchi methods as well as implementation of a streamline tracing technique. Results of applications are shown for several geometeries including: three dimensional thruster nozzles with round or super elliptic throats and rectangualar exits, two- and three-dimensional thrusters installed within a bell nozzle, and three dimensional thrusters with round throats and sector shaped exits. Due to the novel designs considered for this study, there is little experience which can be used to guide the effort and limit the design space. With a nearly infinite parameter space to explore, simple parametric design studies cannot possibly search the entire design space within the time frame required to impact the design cycle. For this reason, robust and efficient optimization methods are required to explore and exploit the design space to achieve high performance engine designs. Five case studies which examine the application of various techniques in the engineering environment are presented in this paper.