DESIGN, FABRICATION, AND TESTING OF A CESIUM ION ROCKET ENGINE.
Design, fabrication, and testing of a cesium ion rocket engine
CESIUM ENGINE↗
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DESIGN, FABRICATION, AND TESTING OF A CESIUM ION ROCKET ENGINE.
Design, fabrication, and testing of a cesium ion rocket engine
ION ENGINE↗
Knowledge Engineering for Preservation and Future use of Institutional Knowledge
This Project has two main thrusts-preservation of special knowledge and its useful representation via computers. NASA is losing the expertise of its engineers and scientists who put together the great missions of the past. We no longer are landing men on the moon. Some of the equipment still used today (such as the RL-10 rocket) was designed decades ago by people who are now retiring. Furthermore, there has been a lack, in some areas of technology, of new projects that overlap with the old and that would have provided opportunities for monitoring by senior engineers of the young ones. We are studying this problem and trying out a couple of methods of soliciting and recording rare knowledge from experts. One method is that of Concept Maps which produces a graphical interface to knowledge even as it helps solicit that knowledge. We arranged for experienced help in this method from John Coffey of the Institute of Human and Machine Technology at the University of West Florida. A second method which we plan to try out in May, is a video-taped review of selected failed missions (e.g., the craft tumbled and blew up). Five senior engineers (most already retired from NASA) will, as a team, analyze available data, illustrating their thought processes as they try to solve the problem of why a space craft failed to complete its mission. The session will be captured in high quality audio and with at least two video cameras. The video can later be used to plan future concept mapping interviews and, in edited form, be a product in itself. Our computer representations of the amassed knowledge may eventually, via the methods of expert systems, be joined with other software being prepared as a suite of tools to aid future engineers designing rocket engines. In addition to representation by multimedia concept maps, we plan to consider linking vast bodies of text (and other media) by hypertexting methods.
Moreman, Douglas↗
Design, development, and testing of a 1000 pound /4450 N/ thrust FLOX-propane ablative rocket engine
Design, development, and testing of 1000 pound thrust FLOX-propane ablative rocket engine
Pauli, A. J.↗
Linear rocket engine design-fabrication-testing
A new rocket engine concept that is presently being evaluated offers significant performance, cost, and configurational advantages. The Linear Rocket Engine System, (LRES) combines the unique performance and operational advantages of the aerospike nozzle with the configuration versatility of low cost modular combustors, which results in a high-performance rocket engine package designed specifically for use in advanced configuration vehicles. This paper describes the design, fabrication, and testing of the LRES concept to evaluate its potential for vehicle integration. The program was conducted under the sponsorship of NASA's Marshall Space Flight Center.
Fuller, P. N.↗
Design of Liquid Propellant Rocket Engines Second Edition
This book intends to build a bridge for the student and the young engineer: to link the rocket propulsion fundamentals and elements (which are well covered in the literature) with the actual rocket engine design and development work as it is carried out in industry (which is very little, if at all covered in literature). The book attempts to further the understanding of the realistic application of liquid rocket propulsion theories, and to help avoid or at least reduce time and money consuming errors and disappointments. In so doing, it also attempts to digest and consolidate numerous closely related subjects, hitherto often treated as separate, bringing them up to date at the same time. The book was written "on the job" for use by those active in all phases of engine systems design, development, and application, in industry as well as government agencies. Since it addresses itself to human beings set out to create new machines, rather than describing machines about to dominate man, the language chosen may not always be "functional" in the strict sense of the word. The book presents sufficient detail to familiarize and educate thoroughly those responsible for various aspects of liquid propellant rocketry, including engine systems design, engine development, and flight vehicle application. It should enable the rocket engineer to conduct, independently, complete or partial engine systems preliminary detail designs and to understand and judge the activities in, and the problems, limitations, and "facts of life~ of the various subsystems making up a complete engine system. It also attempts to educate those ultimately interested in specialized subsystems and component design (thrust chamber, turbopump, control valves, etc.) about their own as well as neighboring subsystems and about the complete engine system. This should enable the student to prepare realistic analytical calculations and design layouts with a long headstart toward the final specialized designs for subsystem production release. Special emphasis has been placed on engine flight application to stimulate engine systems and subsystem designers to think in these terms from the outset. The book is intended as a textbook, with specific consideration of the teacher without industry experience. We hope it will stimulate those desiring to specialize in the area of a rocket engine subsystem by supplying adequate information to enable them to benefit fully from the specialized literature. Thus, it provides a realistic expert introduction for those joining the liquid propellant rocket engine field.
Dieter K Huzel↗
A survey of instabilities within centrifugal pumps and concepts for improving the flow range of pumps in rocket engines
Design features and concepts that have primary influence on the stable operating flow range of propellant-feed centrifugal turbopumps in a rocket engine are discussed. One of the throttling limitations of a pump-fed rocket engine is the stable operating range of the pump. Several varieties of pump hydraulic instabilities are mentioned. Some pump design criteria are summarized and a qualitative correlation of key parameters to pump stall and surge are referenced. Some of the design criteria were taken from the literature on high pressure ratio centrifugal compressors. Therefore, these have yet to be validated for extending the stable operating flow range of high-head pumps. Casing treatment devices, dynamic fluid-damping plenums, backflow-stabilizing vanes and flow-reinjection techniques are summarized. A planned program was undertaken at LeRC to validate these concepts. Technologies developed by this program will be available for the design of turbopumps for advanced space rocket engines for use by NASA in future space missions where throttling is essential.
Veres, Joseph P.↗
Small High-Speed Self-Acting Shaft Seals for Liquid Rocket Engines
Design analysis, fabrication, and experimental evaluation were performed on three self-acting facetype LOX seal designs and one circumferential-type helium deal design. The LOX seals featured Rayleigh step lift pad and spiral groove geometry for lift augmentation. Machined metal bellows and piston ring secondary seal designs were tested. The helium purge seal featured floating rings with Rayleigh step lift pads. The Rayleigh step pad piston ring and the spiral groove LOX seals were successfully tested for approximately 10 hours in liquid oxygen. The helium seal was successfully tested for 24 hours. The shrouded Rayleigh step hydrodynamic lift pad LOX seal is feasible for advanced, small, high-speed oxygen turbopumps.
Burcham, R. E.↗
Designing Liquid Rocket Engine Injectors for Performance, Stability, and Cost
NASA is developing the Space Launch System (SLS) for crewed exploration missions beyond low Earth orbit. Marshall Space Flight Center (MSFC) is designing rocket engines for the SLS Advanced Booster (AB) concepts being developed to replace the Shuttle-derived solid rocket boosters. One AB concept uses large, Rocket-Propellant (RP)-fueled engines that pose significant design challenges. The injectors for these engines require high performance and stable operation while still meeting aggressive cost reduction goals for access to space. Historically, combustion stability problems have been a critical issue for such injector designs. Traditional, empirical injector design tools and methodologies, however, lack the ability to reliably predict complex injector dynamics that often lead to combustion stability. Reliance on these tools alone would likely result in an unaffordable test-fail-fix cycle for injector development. Recently at MSFC, a massively parallel computational fluid dynamics (CFD) program was successfully applied in the SLS AB injector design process. High-fidelity reacting flow simulations were conducted for both single-element and seven-element representations of the full-scale injector. Data from the CFD simulations was then used to significantly augment and improve the empirical design tools, resulting in a high-performance, stable injector design.
Westra, Douglas G.↗
Orbital transfer rocket engine technology 7.5K-LB thrust rocket engine preliminary design
A preliminary design of an advanced LOX/LH2 expander cycle rocket engine producing 7,500 lbf thrust for Orbital Transfer vehicle missions was completed. Engine system, component and turbomachinery analysis at both on design and off design conditions were completed. The preliminary design analysis results showed engine requirements and performance goals were met. Computer models are described and model outputs are presented. Engine system assembly layouts, component layouts and valve and control system analysis are presented. Major design technologies were identified and remaining issues and concerns were listed.
Harmon, T. J.↗
Turbopump Design and Analysis Approach for Nuclear Thermal Rockets
A rocket propulsion system, whether it is a chemical rocket or a nuclear thermal rocket, is fairly complex in detail but rather simple in principle. Among all the interacting parts, three components stand out: they are pumps and turbines (turbopumps), and the thrust chamber. To obtain an understanding of the overall rocket propulsion system characteristics, one starts from analyzing the interactions among these three components. It is therefore of utmost importance to be able to satisfactorily characterize the turbopump, level by level, at all phases of a vehicle design cycle. Here at NASA Glenn Research Center, as the starting phase of a rocket engine design, specifically a Nuclear Thermal Rocket Engine design, we adopted the approach of using a high level system cycle analysis code (NESS) to obtain an initial analysis of the operational characteristics of a turbopump required in the propulsion system. A set of turbopump design codes (PumpDes and TurbDes) were then executed to obtain sizing and performance characteristics of the turbopump that were consistent with the mission requirements. A set of turbopump analyses codes (PUMPA and TURBA) were applied to obtain the full performance map for each of the turbopump components; a two dimensional layout of the turbopump based on these mean line analyses was also generated. Adequacy of the turbopump conceptual design will later be determined by further analyses and evaluation. In this paper, descriptions and discussions of the aforementioned approach are provided and future outlooks are discussed.
Chen, Shu-cheng S.↗
1025:1 Area Ratio Nozzle Evaluated at High Combustion Chamber Pressure
A recently completed experimental test program obtained performance data on an optimally contoured nozzle with an exit-to-throat area ratio of 1025:1 and on a truncated version of this nozzle with an area ratio of 440:1. The nozzles were tested with gaseous hydrogen and liquid oxygen propellants at combustion chamber pressures of 12.4 to 16.5 mPa (1800 to 2400 psia). Testing was conducted in the altitude test capsule at the NASA Lewis Research Center's Rocket Engine Test Facility (RETF), and results were compared with analytical performance predictions. This testing builds on previous work with this nozzle at Lewis, where testing was completed at nominal chamber pressure of 350 psia. High-area-ratio nozzles have long been sought as a means to increase the performance of spacebased rocket engines. However, as the area ratio increases, the physical size and weight of the nozzle also increase. As a result, engine and vehicle designers must make tradeoffs between nozzle size and performance enhancement. Until this test program, very little experimental data existed on the performance of the high-area-ratio nozzles used in rocket engine designs. The computer codes being used by rocket engine designers rely on data extrapolated from tests of low-area-ratio nozzles, and these extrapolations do not always provide the accuracy needed for a reliable design assessment. Therefore, we conducted this high-area-ratio nozzle testing program to provide performance data for use in rocket engine design and analysis computer codes. The nozzle had a nominal 2.54-cm- (1-in.-) diameter throat, an exit diameter of 81.3-cm (32.0-in.) at an exit-to-throat area ratio of 1025, and a length of 128.6 cm (50.6 in.). Testing was conducted in an altitude test capsule to simulate the static pressure at altitude by vacuum pumping. Data such as propellant mass flow, oxidizer-to-fuel mixture, and thrust were measured. These measurements were then used to calculate performance factors such as the thrust coefficient, the characteristic exhaust velocity efficiency, and the vacuum specific impulse. In addition, the nozzle temperature was measured to calculate the amount of heat transferred from the combustion gases to the nozzle.
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Computational fluid dynamic design of rocket engine pump components
Integration of computational fluid dynamics (CFD) for design and analysis of turbomachinery components is needed as the requirements of pump performance and reliability become more stringent for the new generation of rocket engine. A fast grid generator, designed specially for centrifugal pump impeller, which allows a turbomachinery designer to use CFD to optimize the component design will be presented. The CFD grid is directly generated from the impeller blade G-H blade coordinates. The grid points are first generated on the meridional plane with the desired clustering near the end walls. This is followed by the marching of grid points from the pressure side of one blade to the suction side of a neighboring blade. This fast grid generator has been used to optimize the consortium pump impeller design. A grid dependency study has been conducted for the consortium pump impeller. Two different grid sizes, one with 10,000 grid points and one with 80,000 grid points were used for the grid dependency study. The effects of grid resolution on the turnaround time, including the grid generation and completion of the CFD analysis, is discussed. The impeller overall mass average performance is compared for different designs. Optimum design is achieved through systematic change of the design parameters. In conclusion, it is demonstrated that CFD can be effectively used not only for flow analysis but also for design and optimization of turbomachinery components.
Chen, Wei-Chung↗
LOX/hydrocarbon rocket engine analytical design methodology development and validation. Volume 1: Executive summary and technical narrative
During the past three decades, an enormous amount of resources were expended in the design and development of Liquid Oxygen/Hydrocarbon and Hydrogen (LOX/HC and LOX/H2) rocket engines. A significant portion of these resources were used to develop and demonstrate the performance and combustion stability for each new engine. During these efforts, many analytical and empirical models were developed that characterize design parameters and combustion processes that influence performance and stability. Many of these models are suitable as design tools, but they have not been assembled into an industry-wide usable analytical design methodology. The objective of this program was to assemble existing performance and combustion stability models into a usable methodology capable of producing high performing and stable LOX/hydrocarbon and LOX/hydrogen propellant booster engines.
Pieper, Jerry L.↗
Advancing the State-of-the-Practice for Liquid Rocket Engine Injector Design
Current shortcomings in both the overall injector design process and its underlying combustion stability assessment methodology are rooted in the use of empirically based or low fidelity representations of complex physical phenomena and geometry details that have first order effects on performance, thermal environments and combustion stability. The result is a design and analysis capability that is often inadequate to reliably arrive at a suitable injector design in an efficient manner. Specifically, combustion instability has been particularly difficult to predict and mitigate. Large hydrocarbon-fueled booster engines have been especially problematic in this regard. Where combustion instability has been a problem, costly and time-consuming redesign efforts have often been an unfortunate consequence. This paper presents an overview of a recently completed effort at NASA Marshall Space Flight Center to advance the state-of-the-practice for liquid rocket engine injector design. Multiple perturbations of a gas-centered swirl coaxial (GCSC) element that burned gaseous oxygen and RP-1 were designed, assessed for combustion stability, and tested. Three designs, one stable, one marginally unstable and one unstable, were used to demonstrate both an enhanced overall injector design process and an improved combustion stability assessment process. High-fidelity results from state-of-the-art computational fluid dynamics CFD simulations were used to substantially augment and improve the injector design methodology. The CFD results were used to inform and guide the overall injector design process. They were also used to upgrade selected empirical or low-dimensional quantities in the ROCket Combustor Interactive Design (ROCCID) stability assessment tool. Hot fire single element injector testing was used to verify both the overall injector designs and the stability assessments. Testing was conducted at the Air Force Research Laboratory and at Purdue University. Companion papers provide details of the overall injector design process, full- and sub-scale testing, ROCCID-based stability assessments and the CFD simulations.
Tucker, P. K.↗
Designing Liquid Rocket Engine Injectors for Performance, Stability, and Cost
NASA is using computational fluid dynamics (CFD) simulations to lower the cost and increase the performance and stability of fuel injector designs for next-generation liquid rocket engines (LREs). The Loci-STREAM CFD code is used to simulate the complex combustion processes inside the LRE. These analyses enable efficient evaluation of the performance and stability characteristics of injector design concepts, while decreasing reliance on the costly test-fail-fix cycle of traditional design approaches. These injector simulations were recently employed as a key part of the design process for an Advanced Booster concept for NASA's heavy-lift Space Launch System (SLS).
Westra, Douglas G.↗
Revised Point of Departure Design Options for Nuclear Thermal Propulsion
In an effort to further refine potential point of departure nuclear thermal rocket engine designs, four proposed engine designs representing two thrust classes and utilizing two different fuel matrix types are designed and analyzed from both a neutronics and thermodynamic cycle perspective. Two of these nuclear rocket engine designs employ a tungsten and uranium dioxide cermet (ceramic-metal) fuel with a prismatic geometry based on the ANL-200 and the GE-710, while the other two designs utilize uranium-zirconium-carbide in a graphite composite fuel and a prismatic fuel element geometry developed during the Rover/NERVA Programs. Two engines are analyzed for each fuel type, a small criticality limited design and a 111 kN (25 klbf) thrust class engine design, which has been the focus of numerous manned mission studies, including NASA's Design Reference Architecture 5.0. slightly higher T/W ratios, but they required substantially more 235U.
Nuclear Thermal Rockets↗
Solid propellant processing factor in rocket motor design
The ways are described by which propellant processing is affected by choices made in designing rocket engines. Tradeoff studies, design proof or scaleup studies, and special design features are presented that are required to obtain high product quality, and optimum processing costs. Processing is considered to include the operational steps involved with the lining and preparation of the motor case for the grain; the procurement of propellant raw materials; and propellant mixing, casting or extrusion, curing, machining, and finishing. The design criteria, recommended practices, and propellant formulations are included.
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