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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Flow Separation Side Loads Excitation of Rocket Nozzle FEM

Modern rocket nozzles are designed to operate over a wide range of altitudes, and are also built with large aspect ratios to enable high efficiencies. Nozzles designed to operate over specific regions of a trajectory are being replaced in modern launch vehicles by those that are designed to operate from earth to orbit. This is happening in parallel with modern manufacturing and wall cooling techniques allowing for larger aspect ratio nozzles to be produced. Such nozzles, though operating over a large range of altitudes and ambient pressures, are typically designed for one specific altitude. Above that altitude the nozzle flow is 'underexpanded' and below that altitude, the nozzle flow is 'overexpanded'. In both conditions the nozzle produces less than the maximum possible thrust at that altitude. Usually the nozzle design altitude is well above sea level, leaving the nozzle flow in an overexpanded state for its start up as well as for its ground testing where, if it is a reusable nozzle such as the Space Shuttle Main Engine (SSME), the nozzle will operate for the majority of its life. Overexpansion in a rocket nozzle presents the critical, and sometimes design driving, problem of flow separation induced side loads. To increase their understanding of nozzle side loads, engineers at MSFC began an investigation in 2000 into the phenomenon through a task entitled "Characterization and Accurate Modeling of Rocket Engine Nozzle Side Loads", led by A. Brown. The stated objective of this study was to develop a methodology to accurately predict the character and magnitude of nozzle side loads. The study included further hot-fire testing of the MC-l engine, cold flow testing of subscale nozzles, CFD analyses of both hot-fire and cold flow nozzle testing, and finite element (fe.) analysis of the MC-1 engine and cold flow tested nozzles. A follow on task included an effort to formulate a simplified methodology for modeling a side load during a two nodal diameter fluid/structure interaction for a single moment in time.

Smalley, Kurt B.↗
DOE OSTI2020

Demonstrated Low Pressure Loss Inlet and Low Equivalence Ratio Operation of a Rotating Detonation Engine (RDE) for Power Generation

Presentation. An Aerojet Rocketdyne (AR) program was funded by the National Energy Technology Laboratory (NETL), part of the U.S. Department of Energy, to evaluate the benefits of an RDE in a turbine power plant system. Aerojet Rocketdyne subcontracted a variety of support for the program with efforts in modeling, diagnostic techniques, and test campaigns. Over the span of the program more than 700 hot fire tests were conducted at 4 facilities with 7 RDE assemblies. This presentation will cover results from the final test campaign conducted by Aerojet Rocketdyne.

03 NATURAL GAS↗
NASA NTRS1972

FLOX/MMH rocket engine assemblies

A 6-month program was conducted to fabricate, acceptance test, and deliver to JPL two FLOX/MMH rocket engine assemblies. Acceptance testing consisted of injector cold flows and 15-second-duration hot firings with the engine assemblies. An additional objective of the program was to determine the feasibility of utilizing FLOX/MMH thrust chamber components with the F2/N2H4 propellant combination. Feasibility studies consisted of analysis, cold flow, and comparative F2/N2H4-FLOX/MMH calorimeter hot fire testing, followed by a 500-second duration F2/N2H4 demonstration test.

Source record↗
NASA NTRS1982

Evaluation of candidate stirling engine heater tube alloys at 820 deg and 860 deg C

Seven commercial alloys were evaluated in Stirling simulator materials rigs. Five iron base alloys (N-155, A-286, Incoloy 800, 19-9DL, and 316 stainless steel), one nickel base alloy (Inconel 718), and one cobalt base alloy (HS-188) were tested in the form of thin wall tubing in a diesel fuel fired test rig. Tubes filled with hydrogen or helium at gas pressure of 21.6 MPa and temperatures of 820 and 860 C were endurance tested for 1000 and 535 hours, respectively. Results showed that under these conditions hydrogen permeated rapidly through the tube walls, thus requiring refilling during each five hour cycle. Helium was readily contained, exhibiting no measurable loss by permeation. Helium filled tubes tested at 860 C all exhibited creep-rupture failures within the 535 hour endurance test. Subsequent tensile test evaluation after removal from the rig indicated reduced room temperature ductility for some hydrogen-filled tubes compared to helium-filled tubes, suggesting possible hydrogen embrittlement in these alloys.

Misencik, J. A.↗
NASA NTRS1983

Combustion performance and heat transfer characterization of LOX/hydrocarbon type propellants

An evaluation liquid oxygen (LOX) and various hydrocarbon fuels as low cost alternative propellants suitable for future space transportation system applications was done. The emphasis was directed toward low earth orbit maneuvering engine and reaction control engine systems. The feasibility of regeneratively cooling an orbit maneuvering thruster was analytically determined over a range of operating conditions from 100 to 1000 psia chamber pressure and 1000 to 10,000-1bF thrust, and specific design points were analyzed in detail for propane, methane, RP-1, ammonia, and ethanol; similar design point studies were performed for a film-cooled reaction control thruster. Heat transfer characteristics of propane were experimentally evaluated in heated tube tests. Forced convection heat transfer coefficients were determined. Seventy-seven hot firing tests were conducted with LOX/propane and LOX/ethanol, for a total duration of nearly 1400 seconds, using both heat sink and water-cooled calorimetric chambers. Combustion performance and stability and gas-side heat transfer characteristics were evaluated.

Michel, R. W.↗
NASA NTRS1993

Spacecraft propulsion research facility (B-2) at the Lewis Research Center, Plum Brook Station

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.

Klein, William E.↗
NASA NTRS1987

Experimental thrust performance of a high-area-ratio rocket nozzle

An experimental investigation was conducted to determine the thrust performance attainable from high-area-ratio rocket nozzles. A modified Rao-contoured nozzle with an expansion area of 1030 was test fired with hydrogen-oxygen propellants at altitude conditions. The nozzle was also tested as a truncated nozzle, at an expansion area ratio of 428. Thrust coefficient and thrust coefficient efficiency values are presented for each configuration at various propellant mixture ratios (oxygen/fuel). Several procedural techniques were developed permitting improved measurement of nozzle performance. The more significant of these were correcting the thrust for the aneroid effects, determining the effective chamber pressure, and referencing differential pressure transducers to a vacuum reference tank.

Pavli, Albert J.↗
NASA NTRS1986

Experimental thrust performance of a high area-ratio rocket nozzle

An experimental investigation was conducted to determine the thrust performance attainable from high-area-ratio rocket nozzles. A modified Rao-contoured nozzle with an expansion area of 1030 was test fired with hydrogen-oxygen propellants at altitude conditions. The nozzle was also tested as a truncated nozzle, at an expansion area ratio of 428. Thrust coefficient and thrust coefficient efficiency values are presented for each configuration at various propellant mixture ratios (oxygen/fuel). Several procedural techniques were developed permitting improved measurement of nozzle performance. The more significant of these were correcting the thrust for the aneroid effects, determining the effective chamber pressure, and referencing differential pressure transducers to a vacuum reference tank.

Pavli, A. J.↗
NASA NTRS2005

Gas-Centered Swirl Coaxial Liquid Injector Evaluations

Development of Liquid Rocket Engines is expensive. Extensive testing at large scales usually required. In order to verify engine lifetime, large number of tests required. Limited Resources available for development. Sub-scale cold-flow and hot-fire testing is extremely cost effective. Could be a necessary (but not sufficient) condition for long engine lifetime. Reduces overall costs and risk of large scale testing. Goal: Determine knowledge that can be gained from sub-scale cold-flow and hot-fire evaluations of LRE injectors. Determine relationships between cold-flow and hot-fire data.

Cohn, A. K.↗
NASA NTRS2013

HESTIA Commodities Exchange Pallet and Sounding Rocket Test Stand

During my Spring 2016 internship, my two major contributions were the design of the Commodities Exchange Pallet and the design of a test stand for a 100 pounds-thrust sounding rocket. The Commodities Exchange Pallet is a prototype developed for the Human Exploration Spacecraft Testbed for Integration and Advancement (HESTIA) program. Under the HESTIA initiative the Commodities Exchange Pallet was developed as a method for demonstrating multi-system integration thru the transportation of In-Situ Resource Utilization produced oxygen and water to a human habitat. Ultimately, this prototype's performance will allow for future evaluation of integration, which may lead to the development of a flight capable pallet for future deep-space exploration missions. For HESTIA, my main task was to design the Commodities Exchange Pallet system to be used for completing an integration demonstration. Under the guidance of my mentor, I designed, both, the structural frame and fluid delivery system for the commodities pallet. The fluid delivery system includes a liquid-oxygen to gaseous-oxygen system, a water delivery system, and a carbon-dioxide compressors system. The structural frame is designed to meet safety and transportation requirements, as well as the ability to interface with the ER division's Portable Utility Pallet. The commodities pallet structure also includes independent instrumentation oxygen/water panels for operation and system monitoring. My major accomplishments for the commodities exchange pallet were the completion of the fluid delivery systems and the structural frame designs. In addition, parts selection was completed in order to expedite construction of the prototype, scheduled to begin in May of 2016. Once the commodities pallet is assembled and tested it is expected to complete a fully integrated transfer demonstration with the ISRU unit and the Environmental Control and Life Support System test chamber in September of 2016. In addition to the development of the Commodities Exchange Pallet, I also assisted in preparation for testing the upper stage of a sounding rocket developed as a Center Innovation Fund project. The main objective of this project is to demonstrate the integration between a propulsion system and a solid oxide fuel cell (SOFC). The upper stage and SOFC are scheduled to complete an integrated test in August of 2016. As part of preparation for scheduled testing, I was responsible for designing the upper stage's test stand/support structure and main engine plume deflector to be used during hot-fire testing (fig. 3). The structural components of the test stand need to meet safety requirements for operation of the propulsion system, which consist of a 100 pounds-thrust main engine and two 15 pounds-thrust reaction control thrusters. My main accomplishment for this project was the completion of the design and the parts selection for construction of the structure, scheduled to begin late April of 2016.

Chaparro, Javier↗
NASA NTRS2017

Coil-On-Plug Ignition for LOX/Methane Liquid Rocket Engines in Thermal Vacuum Environments

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX) / liquid methane rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/methane propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. In order to successfully demonstrate ignition reliability in the vacuum conditions and eliminate corona discharge issues, a coil-on-plug ignition system has been developed. The ICPTA uses spark-plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark-plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp.-2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, Plum Brook testing demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/methane propulsion systems in future spacecraft.

Melcher, John C.↗
NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRSDate not supplied

Nodal Modeling of Tank Pressurization and Draining using a Multi-Node-Ullage Approach

The purpose of the pressurization system in liquid rocket propulsion is to control the pressure in the gas space of the propellant tank (known as the ullage space) and the propellant mass flowrate to the engine. A mathematical model is required to predict the amount of pressurant necessary to ensure that pressure and temperature levels inside the tank remain within acceptable limits and that the propellant pressure leaving the tank satisfies the net positive suction pressure (NPSP) requirement of the pump feeding the engine. Nodal codes typically model tank pressurization and draining using a single node to represent the ullage and a single node to represent the propellant. As the tank drains, the ullage node grows and the propellant node shrinks. The heat transfer between ullage to wall and ullage to propellant is governed by natural convection. Designers of liquid propulsion systems often use empirical correlations to estimate the “Collapse Factor” which represents the ratio of pressurant required with heat transfer and the amount of pressurant required without heat transfer. A single node ullage model of tank pressurization was developed using GFSSP to compute the collapse factor reasonably well and later was used to model tank pressurization during test firing of the FASTRAC rocket engine. The predicted tank pressure compared well with the test data. In the early 1970’s, pressurization and drain tests with liquid methane were performed at NASA Lewis Research Center in a vacuum chamber. A 5 ft diameter spherical aluminum tank was tested to drain from 95% to 5% full using gaseous helium, hydrogen, nitrogen and methane as pressurant. Tests were conducted with different pressurant inlet temperatures and drain times. Measured data include pressurant requirement, amount of pressurant condensed, and ullage and wall temperatures at various heights in the ullage space at the end of draining. A single node GFSSP model was developed to simulate helium pressurization of the methane tank. Predicted helium consumption was 8-23% less than measured. The average error of the six test cases was 16%. A single ullage node with multiple solid node model was developed using Thermal Desktop. Predicted helium consumption compares with the test data within 2%. This paper describes the development of a GFSSP multi-node ullage model of the test configuration and compares the predicted pressurant consumption for both helium and autogenous pressurization using gaseous methane with experimental as well as TD predictions.

Nodal Model↗
NASA NTRS1978

Animal Exposure During Burn Tests

An animal exposure test system (AETS) was designed and fabricated for the purpose of collecting physiological and environmental (temperature) data from animal subjects exposed to combustion gases in large scale fire tests. The AETS consisted of an open wire mesh, two-compartment cage, one containing an exercise wheel for small rodents, and the other containing one rat instrumented externally for electrocardiogram (ECG) and respiration. Cage temperature is measured by a thermistor located in the upper portion of the rat compartment. Animal activity is monitored by the ECG and the records indicate an increase in EMG (electromyograph) noise super-imposed by the increased activity of the torso musculature. Examples of the recordings are presented and discussed as to their significance regarding toxicity of fire gases and specific events occurring during the test. The AETS was shown to be a useful tool in screening materials for the relative toxicity of their outgassing products during pyrolysis and combustion.

Gaume, J. G.↗
NASA NTRS1993

Prediction of rocket plume radiative heating using backward Monte-Carlo method

A backward Monte-Carlo plume radiation code has been developed to predict rocket plume radiative heating to the rocket base region. This paper provides a description of this code and provides sample results. The code was used to predict radiative heating to various locations during test firings of 48-inch solid rocket motors at NASA Marshall Space Flight Center. Comparisons with test measurements are provided. Predictions of full scale sea level Redesigned Solid Rocket Motor (RSRM) and Advanced Solid Rocket Motor (ASRM) plume radiative heating to the Space Shuttle external tank (ET) dome center were also made. A comparison with the Development Flight Instrumentation (DFI) measurements is also provided.

Wang, K. C.↗