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NASA NTRS2005

Rocket Science: The Shuttle's Main Engines, though Old, Are not Forgotten in the New Exploration Initiative

The Space Shuttle Main Engine (SSME), developed 30 years ago, remains a strong candidate for use in the new Exploration Initiative as part of a shuttle-derived heavy-lift expendable booster. This is because the Boeing-Rocket- dyne man-rated SSME remains the most highly efficient liquid rocket engine ever developed. There are only enough parts for 12-15 existing SSMEs, however, so one NASA option is to reinitiate SSME production to use it as a throw-away, as opposed to a reusable, powerplant for NASA s new heavy-lift booster.

Covault, Craig↗

NASA NTRS2005

Matlab GUI for a Fluid Mixer

The Test and Engineering Directorate at NASA John C. Stennis Space Center developed an interest to study the modeling, evaluation, and control of a liquid hydrogen (LH2) and gas hydrogen (GH2) mixer subsystem of a ground test facility. This facility carries out comprehensive ground-based testing and certification of liquid rocket engines including the Space Shuttle Main engine. A software simulation environment developed in MATLAB/SIMULINK (M/S) will allow NASA engineers to test rocket engine systems at relatively no cost. In the progress report submitted in February 2004, we described the development of two foundation programs, a reverse look-up application using various interpolation algorithms, a variety of search and return methods, and self-checking methods to reduce the error in returned search results to increase the functionality of the program. The results showed that these efforts were successful. To transfer this technology to engineers who are not familiar with the M/S environment, a four-module GUI was implemented allowing the user to evaluate the mixer model under open-loop and closed-loop conditions. The progress report was based on an udergraduate Honors Thesis by Ms. Jamie Granger Austin in the Department of Electrical Engineering and Computer Science at Tulane University, during January-May 2003, and her continued efforts during August-December 2003. In collaboration with Dr. Hanz Richter and Dr. Fernando Figueroa we published these results in a NASA Tech Brief due to appear this year. Although the original proposal in 2003 did not address other components of the test facility, we decided in the last few months to extend our research and consider a related pressurization tank component as well. This report summarizes the results obtained towards a Graphical User Interface (GUI) for the evaluation and control of the hydrogen mixer subsystem model and for the pressurization tank each taken individually. Further research would combine the two components - mixer and tank, for a more realistic simulation tool.

Barbieri, Enrique↗

NASA NTRS1993

Combustion chamber analysis code

A three-dimensional, time dependent, Favre averaged, finite volume Navier-Stokes code has been developed to model compressible and incompressible flows (with and without chemical reactions) in liquid rocket engines. The code has a non-staggered formulation with generalized body-fitted-coordinates (BFC) capability. Higher order differencing methodologies such as MUSCL and Osher-Chakravarthy schemes are available. Turbulent flows can be modeled using any of the five turbulent models present in the code. A two-phase, two-liquid, Lagrangian spray model has been incorporated into the code. Chemical equilibrium and finite rate reaction models are available to model chemically reacting flows. The discrete ordinate method is used to model effects of thermal radiation. The code has been validated extensively against benchmark experimental data and has been applied to model flows in several propulsion system components of the SSME and the STME.

Przekwas, A. J.↗

NASA NTRS2003

The National Aerospace Initiative (NAI): Technologies For Responsive Space Access

The Secretary of Defense has set new goals for the Department of Defense (DOD) to transform our nation's military forces. The Director for Defense Research and Engineering (DDR&E) has responded to this challenge by defining and sponsoring a transformational initiative in Science and Technology (S&T) - the National Aerospace Initiative (NAI) - which will have a fundamental impact on our nation's military capabilities and on the aerospace industry in general. The NAI is planned as a joint effort among the tri-services, DOD agencies and National Aeronautics and Space Administration (NASA). It is comprised of three major focus areas or pillars: 1) High Speed Hypersonics (HSH), 2) Space Access (SA), and 3) Space Technology (ST). This paper addresses the Space Access pillar. The NAI-SA team has employed a unique approach to identifying critical technologies and demonstrations for satisfying both military and civilian space access capabilities needed in the future. For planning and implementation purposes the NAI-SA is divided into five technology subsystem areas: Airframe, Propulsion, Flight Subsystems, Operations and Payloads. Detailed technology roadmaps were developed under each subsystem area using a time-phased, goal oriented approach that provides critical space access capabilities in a timely manner and involves subsystem ground and flight demonstrations. This S&T plan addresses near-term (2009), mid-term (2016), and long-term (2025) goals and objectives for space access. In addition, system engineering and integration approach was used to make sure that the plan addresses the requirements of the end users. This paper describes in some detail the technologies in NAI-Space Access pillar. Some areas of emphasis are: high temperature materials, thermal protection systems, long life, lightweight, highly efficient airframes, metallic and composite cryotanks, advanced liquid rocket engines, integrated vehicle health monitoring and management, highly operable systems and payloads. Implementation strategies for NAI are also described.

Culbertson, Andrew↗

NASA NTRS1994

Pressure loss modulus correlation for Delta p across uniformly distributed-loss devices

A dimensionless group, called a pressure loss modulus (N(sub PL)), is introduced that, in conjunction with an appropriately defined Reynolds number, is of considerable engineering utility in correlating steady-state Delta p vs flow calibration data and subsequently as a predictor, using the same or a different fluid, in uniformly distributed pressure loss devices. It is particularly useful under operation in the transition regime. Applications of this simple bivariate correlation to three diverse devices of particular interest for small liquid rocket engine fluid systems are discussed: large L/D capillary tube restrictors, packed granular catalyst beds, and stacked vortex-loss disk restrictors.

Nunz, Gregory J.↗

NASA NTRS2019

Multi-Node Modeling of Cryogenic Tank Pressurization System Using Generalized Fluid System Simulation Program

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.

Bandyopadhyay, Alak↗

NASA NTRS1992

A numerical model for atomization-spray coupling in liquid rocket thrust chambers

The physical process of atomization is an important consideration in the stable operation of liquid rocket engines. Many spray combustion computational fluid dynamics (CFD) codes do not include an atomization sub-model but assume arbitrary drop size distributions, drop initial locations, and velocities. A method of coupling an atomization model with the spray model in a REFLEQS CFD code is presented. This method is based on a jet-embedding technique in which the equations governing the liquid jet core are solved separately using the surrounding gas phase conditions. The droplet initial conditions are calculated using a stability analysis appropriate for the atomization regime of liquid jet break-up. This novel coupling model is used to analyze the SSME fuel preburner single injector flow. Results of the diffusion flame characteristics in a single injection element will be presented. The effect of relative velocity, mixture ratio and droplet initial conditions will be shown. The predictions of present atomization model is compared with that of the widely used CICM correlation. The results are also compared with the predictions of volume-of-fluid method.

M. G. Giridharan↗

NASA NTRS2010

Performance and Stability Analyses of Rocket Combustion Devices Using Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in flight-qualified engine systems, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented programs with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, NASA Marshall Space Flight Center has conducted combustion, performance, and combustion stability analyses of several of the configurations on these programs. This paper summarizes these analyses. Test and analysis results of impinging and coaxial element injectors using liquid oxygen and liquid methane propellants are included. Several cases with gaseous methane are included for reference. Several different thrust chamber configurations have been modeled, including thrust chambers with multi-element like-on-like and swirl coax element injectors tested at NASA MSFC, and a unielement chamber with shear and swirl coax injectors tested at The Pennsylvania State University. Configurations were modeled with two one-dimensional liquid rocket combustion analysis codes, the Rocket Combustor Interaction Design and Analysis (ROCCID), and the Coaxial Injector Combustion Model (CICM). Significant effort was applied to show how these codes can be used to model combustion and performance with oxygen/methane propellants a priori, and what anchoring or calibrating features need to be applied or developed in the future. This paper describes the test hardware configurations, presents the results of all the analyses, and compares the results from the two analytical methods.

Hulka, James R.↗

NASA NTRS1994

Simplex turbopump design

Turbomachinery used in liquid rocket engines typically are composed of complex geometries made from high strength-to-weight super alloys and have long design and fabrication cycle times (3 to 5 years). A simple, low-cost turbopump is being designed in-house to demonstrate the ability to reduce the overall cost to $500K and compress life cycle time to 18 months. The simplex turbopump was designed to provide a discharge pressure of 1500 psia of liquid oxygen at 90 lbm/s. The turbine will be powered by gaseous oxygen. This eliminates the need for an inter-propellant seal typically required to separate the fuel-rich turbine gases from the liquid oxygen pump components. Materials used in the turbine flow paths will utilize existing characterized metals at 800 deg R that are compatible with a warm oxygen environment. This turbopump design would be suitable for integration with a 40 K pound thrust hybrid motor that provides warm oxygen from a tapped-off location to power the turbine. The preliminary and detailed analysis was completed in a year by a multiple discipline, concurrent engineering team. Manpower, schedule, and cost data were tracked during the process for a comparison to the initial goal. The Simplex hardware is the procurement cycle with the expectation of the first test to occur approximately 1.5 months behind the original schedule goal.

Marsh, Matt↗

NASA NTRS2004

Hydrodynamic Modeling of Oxidizer-Rich Staged Combustion Injector Flow

The main objective of this work is to determine the unsteady hydrodynamic characteristics of coaxial swirl atomizers of interest in oxidizer-rich staged combustion (ORSC) liquid rocket engines. To this end, the pseudo-density (homogeneous flow) treatment combined with the Marker-and-Cell (MAC) numerical algorithm has been used to develop an axisymmetric with swirl, two-phase, unsteady model. The numerical model is capable of assessing the time-dependent orifice exit conditions and internal mixing for arbitrary fuel and oxidizer gas injection conditions. Parametric studies have been conducted to determine the effect of geometry, gas properties, and liquid properties on the exit massflow rate and velocity. It has been found that the frequency at which the liquid film oscillates increases as the density ratio and thickness increase, decreases as film thickness and liquid swirl velocity increase, and is unaffected by the mixing length. Additionally, it has been determined that the variation in the massflow rate increases as the liquid swirl velocity and liquid film thickness increase, and decreases as the density ratio, collar thickness, and mixing length increase.

Canino, J. V.↗

NASA NTRS1998

Space Shuttle Main Engine Quantitative Risk Assessment: Illustrating Modeling of a Complex System with a New QRA Software Package

During 1997, a team from Hernandez Engineering, MSFC, Rocketdyne, Thiokol, Pratt & Whitney, and USBI completed the first phase of a two year Quantitative Risk Assessment (QRA) of the Space Shuttle. The models for the Shuttle systems were entered and analyzed by a new QRA software package. This system, termed the Quantitative Risk Assessment System(QRAS), was designed by NASA and programmed by the University of Maryland. The software is a groundbreaking PC-based risk assessment package that allows the user to model complex systems in a hierarchical fashion. Features of the software include the ability to easily select quantifications of failure modes, draw Event Sequence Diagrams(ESDs) interactively, perform uncertainty and sensitivity analysis, and document the modeling. This paper illustrates both the approach used in modeling and the particular features of the software package. The software is general and can be used in a QRA of any complex engineered system. The author is the project lead for the modeling of the Space Shuttle Main Engines (SSMEs), and this paper focuses on the modeling completed for the SSMEs during 1997. In particular, the groundrules for the study, the databases used, the way in which ESDs were used to model catastrophic failure of the SSMES, the methods used to quantify the failure rates, and how QRAS was used in the modeling effort are discussed. Groundrules were necessary to limit the scope of such a complex study, especially with regard to a liquid rocket engine such as the SSME, which can be shut down after ignition either on the pad or in flight. The SSME was divided into its constituent components and subsystems. These were ranked on the basis of the possibility of being upgraded and risk of catastrophic failure. Once this was done the Shuttle program Hazard Analysis and Failure Modes and Effects Analysis (FMEA) were used to create a list of potential failure modes to be modeled. The groundrules and other criteria were used to screen out the many failure modes that did not contribute significantly to the catastrophic risk. The Hazard Analysis and FMEA for the SSME were also used to build ESDs that show the chain of events leading from the failure mode occurence to one of the following end states: catastrophic failure, engine shutdown, or siccessful operation( successful with respect to the failure mode under consideration).

Smart, Christian↗

NASA NTRS2024

Nodal Modeling of Liquid Propellant Feed and Pressurization System

Nodal or network flow modeling plays an important role in the design and operation of the feed and pressurization system of a liquid rocket engine. Model development and execution time is relatively short for nodal codes in comparison to the Navier-Stokes based CFD codes. Nodal models also allow the inclusion of several components into one model to predict the behavior of a larger system. Unlike CFD models, the nodal models do not need very fine discretization of the flow field because they use empirical correlations to model fluid friction and heat transfer. This paper presents several applications of nodal modeling of liquid propellant feed and pressurization systems using the Generalized Fluid System Simulation Program (GFSSP), a nodal code developed at NASA/ Marshall Space Flight Center. GFSSP discretizes the flow field into nodes which are connected by branches. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The momentum equations are solved at the branches to calculate flow rates. Applications include a) tank pressurization by inert gas as well as autogenous pressurization by gaseous propellant, b) submerged pressurization by helium, c) self-pressurization due to boil-off of cryogenic propellant, d) chilldown of a transfer line of a cryogenic propellant feed system, and e) chilldown and filling of a cryogenic tank. Each of the above-mentioned models was verified and validated by comparing with test data.

Nodal Model↗

NASA NTRS2024

Nodal Modeling of Liquid Propellant Feed and Pressurization System

Nodal Model↗

NASA NTRS2010

Combustion and Performance Analyses of Coaxial Element Injectors with Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in a flight-qualified engine system, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented activities with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, the NASA Marshall Space Flight Center has conducted combustion, performance, and combustion stability analyses of several of the configurations. This paper summarizes the analyses of combustion and performance as a follow-up to a paper published in the 2008 JANNAF/LPS meeting. Combustion stability analyses are presented in a separate paper. The current paper includes test and analysis results of coaxial element injectors using liquid oxygen and liquid methane or gaseous methane propellants. Several thrust chamber configurations have been modeled, including thrust chambers with multi-element swirl coax element injectors tested at the NASA MSFC, and a uni-element chamber with shear and swirl coax injectors tested at The Pennsylvania State University. Configurations were modeled with two one-dimensional liquid rocket combustion analysis codes, the Rocket Combustor Interaction Design and Analysis (ROCCID), and the Coaxial Injector Combustion Model (CICM). Significant effort was applied to show how these codes can be used to model combustion and performance with oxygen/methane propellants a priori, and what anchoring or calibrating features need to be applied or developed in the future. This paper describes the test hardware configurations, presents the results of all the analyses, and compares the results from the two analytical methods

Hulka, J. R.↗

NASA NTRS2010

Combustion Stability Analyses of Coaxial Element Injectors with Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in a flight-qualified engine system, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented activities with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, the NASA Marshall Space Flight Center has conducted combustion stability analyses of several of the configurations. This paper presents test data and analyses of combustion stability from the recent PCAD-funded test programs at the NASA MSFC. These test programs used swirl coaxial element injectors with liquid oxygen and liquid methane propellants. Oxygen was injected conventionally in the center of the coaxial element, and swirl was provided by tangential entry slots. Injectors with 28-element and 40-element patterns were tested with several configurations of combustion chambers, including ablative and calorimeter spool sections, and several configurations of fuel injection design. Low frequency combustion instability (chug) occurred with both injectors, and high-frequency combustion instability occurred at the first tangential (1T) transverse mode with the 40-element injector. In most tests, a transition between high-amplitude chug with gaseous methane flow and low-amplitude chug with liquid methane flow was readily observed. Chug analyses of both conditions were conducted using techniques from Wenzel and Szuch and from the Rocket Combustor Interactive Design and Analysis (ROCCID) code. The 1T mode instability occurred in several tests and was apparent by high-frequency pressure measurements as well as dramatic increases in calorimeter-measured heat flux throughout the chamber. Analyses of the transverse mode were conducted with ROCCID and empirical methods such as Hewitt d/V. This paper describes the test hardware configurations, test data, analysis methods, and presents results of the various analyses.

Hulka, J. R.↗

NASA NTRS1993

Development of a computational testbed for numerical simulation of combustion instability

A synergistic hierarchy of analytical and computational fluid dynamic techniques is used to analyze three-dimensional combustion instabilities in liquid rocket engines. A mixed finite difference/spectral procedure is employed to study the effects of a distributed vaporization zone on standing and spinning instability modes within the chamber. Droplet atomization and vaporization are treated by a variety of classical models found in the literature. A multi-zone, linearized analytical solution is used to validate the accuracy of the numerical simulations at small amplitudes for a distributed vaporization region. This comparison indicates excellent amplitude and phase agreement under both stable and unstable operating conditions when amplitudes are small and proper grid resolution is used. As amplitudes get larger, expected nonlinearities are observed. The effect of liquid droplet temperature fluctuations was found to be of critical importance in driving the instabilities of the combustion chamber.

Grenda, Jeffrey↗

NASA NTRSDate not supplied

Simultaneous Orthogonal Imaging for Cold Flow Characterization of Additively Manufactured Injector Elements

Additively manufactured (AM) injectors have the potential to improve characteristic velocity (C*) performance beyond the 90-97% of theoretical C* performance seen by traditionally manufactured (TM) combustion device injectors. Maximized C* performance yields high overall combustion efficiency in all types of combustion devices, particularly liquid rocket engines (LREs) and rotating detonation rocket engines (RDREs). A high degree of propellant atomization and mixedness is required to achieve maximum C* performance and therefore high overall combustion efficiency. This study focused on measuring and comparing the performance of different novel AM injector elements over a broad range of operating conditions under high pressure, cold flow. As part of this work, a high pressure, cold flow experimental spray facility was designed to measure each element’s injector spray patterns under pressures ranging from 50 to 1000 psig and stiffness ratios from 0.5 to 2.0. Preliminary results are presented from orthogonal, simultaneous imaging comparing atomization and spray geometry between quad, trio, pentad, slotted, and triplet impingers in gas-liquid flow.

Ari D Goldman↗

NASA NTRS2002

Incompressible Navier-Stokes Solvers in Primative Variables and their Applications to Steady and Unsteady Flow Simulations

This paper reviews recent progress made in incompressible Navier-Stokes simulation procedures and their application to problems of engineering interest. Discussions are focused on the methods designed for complex geometry applications in three dimensions, and thus are limited to primitive variable formulation. A summary of efforts in flow solver development is given followed by numerical studies of a few example problems of current interest. Both steady and unsteady solution algorithms and their salient features are discussed. Solvers discussed here are based on a structured-grid approach using either a finite -difference or a finite-volume frame work. As a grand-challenge application of these solvers, an unsteady turbopump flow simulation procedure has been developed which utilizes high performance computing platforms. In the paper, the progress toward the complete simulation capability of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of two parallel computing algorithms that have been implemented in the INS3D code. The relative motion of the grid systems for the rotorstator interaction was obtained using overact grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on SCSI Origin 3000 systems at NASA Ames Research Center. The same procedure has been extended to the development of NASA-DeBakey Ventricular Assist Device (VAD) that is based on an axial blood pump. Computational, and clinical analysis of this device are presented.

Kiris, Cetin C.↗