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NASA NTRS1959

Residual Fuel Expulsion from a Simulated 50,000 Pound Thrust Liquid-Propellant Rocket Engine Having a Continuous Rocket-Type Igniter

Tests have been conducted to determine the starting characteristics of a 50,000-pound-thrust rocket engine with the conditions of a quantity of fuel lying dormant in the simulated main thrust chamber. Ignition was provided by a smaller rocket firing rearwardly along the center line. Both alcohol-water and anhydrous ammonia were used as the residual fuel. The igniter successfully expelled the maximum amount of residual fuel (3 1/2 gal) in 2.9 seconds when the igniter.was equipped with a sonic discharge nozzle operating at propellant flow rates of 3 pounds per second. Lesser amounts of residual fuel required correspondingly lower expulsion times. When the igniter was equipped with a supersonic exhaust nozzle operating at a flow of 4 pounds per second, a slightly less effective expulsion rate was encountered.

Messing, Wesley E.↗

NASA NTRS2017

Coil-On-Plug Ignition for Oxygen/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 (LCH4) 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/LCH4 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. A coil-on-plug ignition system has been developed to successfully demonstrate ignition reliability at these conditions while preventing corona discharge issues. 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, hot-fire testing at Plum Brook 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/LCH4 propulsion systems in future spacecraft.

Melcher, John C.↗

NASA NTRS2001

Rocket-Based Combined Cycle Engine Concept Development

The development of rocket-based combined cycle (RBCC) propulsion systems is part of a 12 year effort under both company funding and contract work. The concept is a fixed geometry integrated rocket, ramjet, scramjet, which is hydrogen fueled and uses hydrogen regenerative cooling. The baseline engine structural configuration uses an integral structure that eliminates panel seals, seal purge gas, and closeout side attachments. Engine A5 is the current configuration for NASA Marshall Space Flight Center (MSFC) for the ART program. Engine A5 models the complete flight engine flowpath of inlet, isolator, airbreathing combustor, and nozzle. High-performance rocket thrusters are integrated into the engine enabling both low speed air-augmented rocket (AAR) and high speed pure rocket operation. Engine A5 was tested in GASL's new Flight Acceleration Simulation Test (FAST) facility in all four operating modes, AAR, RAM, SCRAM, and Rocket. Additionally, transition from AAR to RAM and RAM to SCRAM was also demonstrated. Measured performance demonstrated vision vehicle performance levels for Mach 3 AAR operation and ramjet operation from Mach 3 to 4. SCRAM and rocket mode performance was above predictions. For the first time, testing also demonstrated transition between operating modes.

Ratekin, G.↗

NASA NTRS1999

Aerothermo-Structural Analysis of Low Cost Composite Nozzle/Inlet Components

This research is a cooperative effort among the Turbomachinery and Propulsion Division of NASA Glenn, CCMR of NC A&T State University, and the Tuskegee University. The NC A&T is the lead center and Tuskegee University is the participating institution. Objectives of the research were to develop an integrated aerodynamic, thermal and structural analysis code for design of aircraft engine components, such as, nozzles and inlets made of textile composites; conduct design studies on typical inlets for hypersonic transportation vehicles and setup standards test examples and finally manufacture a scaled down composite inlet. These objectives are accomplished through the following seven tasks: (1) identify the relevant public domain codes for all three types of analysis; (2) evaluate the codes for the accuracy of results and computational efficiency; (3) develop aero-thermal and thermal structural mapping algorithms; (4) integrate all the codes into one single code; (5) write a graphical user interface to improve the user friendliness of the code; (6) conduct test studies for rocket based combined-cycle engine inlet; and finally (7) fabricate a demonstration inlet model using textile preform composites. Tasks one, two and six are being pursued. Selected and evaluated NPARC for flow field analysis, CSTEM for in-depth thermal analysis of inlets and nozzles and FRAC3D for stress analysis. These codes have been independently verified for accuracy and performance. In addition, graphical user interface based on micromechanics analysis for laminated as well as textile composites was developed. Demonstration of this code will be made at the conference. A rocket based combined cycle engine was selected for test studies. Flow field analysis of various inlet geometries were studied. Integration of codes is being continued. The codes developed are being applied to a candidate example of trailblazer engine proposed for space transportation. A successful development of the code will provide a simpler, faster and user-friendly tool for conducting design studies of aircraft and spacecraft engines, applicable in high speed civil transport and space missions.

Shivakumar, Kuwigai↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Additive Manufacturing↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

DED↗

NASA NTRS2022

HYPERFIRE

The two main sub-scale, ground-based rocket aerodynamics testing techniques – hot-fire testing and cold-flow testing – pose a series of tradeoffs. Hot-fire testing is generally much more accurate, but is often burdensome, costly, and requires long lead times due to design work, infrastructure preparation, etc. Cold-flow testing is much less expensive and has a rapid turnaround time, but conventional simulants (e.g., nitrogen, steam) used in cold-flow testing yield less accurate results (i.e., results that are not sufficiently representative of test article performance). While researching methods to optimize such tradeoffs, engineers at NASA’s Stennis Space Center discovered that ethane can be tuned to approximate rocket exhaust plumes generated by several common rocket propellants. This led NASA to develop the HYdrocarbon Propellants Enabling Reproduction of Flows in Rocket Engines (HYPERFIRE), a sub-scale, non-reacting flow test system. HYPERFIRE uses heated ethane to enable physical simulation of rocket engines powered by a broad range of propellants in an inexpensive, accurate, and simple fashion.

sub-scale↗

NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2002

Characterization of Side Load Phenomena Using Measurement of Fluid/Structure Interaction

During ground-tests of most production rocket engines over the last 30 years, large asymmetric transient side loads coming from the nozzle and related steady-state vibrational loads within the nozzle have been measured. The widely varying magnitude of these loads has been large enough to fail interfacing components as well as nozzles in these engines. This paper will discuss a comprehensive test and analysis program that has been undertaken to develop a methodology to accurately predict the character and magnitude of this loading. The project to-date has incorporated analytical modeling of both the fluid flow and the nozzle structure and testing of both full-scale and sub-scale rocket nodes. Examination of the test data indicates that one of the two-nodal diameter structural modes may be interacting with flow separation from the nozzle inside-wall in a self-excited or aeroelastic vibration phenomenon. If verified, this observation will be used to develop a methodology for design and analysis. A fuller understanding of the characteristics of this vibration will provide an increase in the accuracy and confidence of side load predictions, which will be critical for the successful construction of the next generation of low-cost, reliable rocket engines.

Brown, Andrew M.↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf) thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) and LOX/Methane (LCH4).

Al6061-RAM2↗

NASA NTRS2011

Hyperthermal Environments Simulator for Nuclear Rocket Engine Development

An arc-heater driven hyperthermal convective environments simulator was recently developed and commissioned for long duration hot hydrogen exposure of nuclear thermal rocket materials. This newly established non-nuclear testing capability uses a high-power, multi-gas, wall-stabilized constricted arc-heater to produce hightemperature pressurized hydrogen flows representative of nuclear reactor core environments, excepting radiation effects, and is intended to serve as a low-cost facility for supporting non-nuclear developmental testing of hightemperature fissile fuels and structural materials. The resulting reactor environments simulator represents a valuable addition to the available inventory of non-nuclear test facilities and is uniquely capable of investigating and characterizing candidate fuel/structural materials, improving associated processing/fabrication techniques, and simulating reactor thermal hydraulics. This paper summarizes facility design and engineering development efforts and reports baseline operational characteristics as determined from a series of performance mapping and long duration capability demonstration tests. Potential follow-on developmental strategies are also suggested in view of the technical and policy challenges ahead. Keywords: Nuclear Rocket Engine, Reactor Environments, Non-Nuclear Testing, Fissile Fuel Development.

Litchford, Ron J.↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

NASA NTRS1989

Design and test of an oxygen turbopump for a dual expander cycle rocket engine

A liquid oxygen (LOX) turbopump with an 860 R gaseous oxygen (GOX) turbine drive was designed for a 3750 lb thrust dual expander cycle rocket engine. This turbopump, which requires no interpropellant seals or system purges, features a 156 hp, single stage, full admission, impulse turbine; an axial flow inducer; a two-stage centrifugal pump with unshrouded impellers; long-life, LOX-lubricated, self-aligning, hydrostatic bearings; and a subcritical rotor design. It is constructed of Monel, a nickel-copper alloy, which has low ignition potential in oxygen. The pump was designed to deliver 34.7 gpm of 4655 psia liquid oxygen at a shaft speed of 75,000 rpm. The dual expander cycle rocket engine and the performance it requires of the LOX turbopump will be discussed as well as the design of the pump, turbine, bearings, and the turbopump rotordynamics. The test program and preliminary test results will also be presented.

Buckmann, P. S.↗

NASA NTRS2009

Liquid Oxygen Rotating Friction Ignition Testing of Aluminum and Titanium with Monel and Inconel for Rocket Engine Propulsion System Contamination Investigation

Metallic contaminant was found in the liquid oxygen (LOX) pre-valve screen of the shuttle main engine propulsion system on two orbiter vehicles. To investigate the potential for an ignition, NASA Johnson Space Center White Sands Test Facility performed (modified) rotating friction ignition testing in LOX. This testing simulated a contaminant particle in the low-pressure oxygen turbo pump (LPOTP) and the high-pressure oxygen turbo pump (HPOTP) of the shuttle main propulsion system. Monel(R) K-500 and Inconel(R) 718 samples represented the LPOTP and HPOTP materials. Aluminum foil tape and titanium foil represented the contaminant particles. In both the Monel(R) and Inconel(R) material configurations, the aluminum foil tape samples did not ignite after 30 s of rubbing. In contrast, all of the titanium foil samples ignited regardless of the rubbing duration or material configuration. However, the titanium foil ignitions did not propagate to the Monel and Inconel materials.

Peralta, S.↗

NASA NTRS1997

Experimental Analysis of a Rocket Based Combined Cycle (RBCC) Engine in a Direct-Connect Test Facility

The object of this study is to investigate the operation of a RBCC at ramjet and scramjet flight conditions using a direct-connect test facility. The apparatus being tested is a single strut-rocket within a dual-mode ram/scramjet combustor. The gaseous hydrogen/oxygen, linear strut-rocket was supplied by Aerojet Propulsion Company. The hardware is being tested in the Direct Connect Supersonic Combustion Test Facility at NASA Langley Research Center. The test facilities hydrogen/oxygen vitiated heater is capable of flight total enthalpies to Mach 8. A Mach 2.5 facility nozzle mates the heater to the combustor duct. The rocket ejector will ordinarily operate in a fuel-rich mode. Additional fuel injection is provided by a pair of parallel injectors located at the base of the strut body. Instrumentation on the test apparatus includes a unique, direct thrust measurement system. Performance predictions for the anticipated test conditions have been made using a one-dimensional, thermodynamic analysis code. Results from the code show the dependence of overall thrust and specific impulse on rocket chamber pressure, rocket fuel equivalence ratio, and overall fuel equivalence ratio. Once the experimental test series begins, the inferred combustion efficiency as a function of axial location and the thermal choke region (where applicable) can also be determined using this code. Upon completion of the experimental test series, measurements will be used to calculate thrust, specific impulse, etc. Measured and calculated values will be compared to those found analytically. If appropriate, the code will be tailored to better predict hardware operation. Conclusions will be drawn as to the fuel-rich rocket's overall effect on ramjet and scramjet performance. Also, comparisons will be made between the integrated thrust calculated from the static pressure taps located along the duct and the thrust measured by the direct thrust measurement system.

K. Nelson↗

NASA NTRS2009

Liquid Oxygen/Liquid Methane Test Results of the RS-18 Lunar Ascent Engine at Simulated Altitude Conditions at NASA White Sands Test Facility

Tests were conducted with the RS-18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA's Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to ~122,000 ft (~37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. LO2 flow ranged from 5.9 - 9.5 lbm/sec (2.7 - 4.3 kg/sec), and LCH4 flow varied from 3.0 - 4.4 lbm/sec (1.4 - 2.0 kg/sec) during the RS-18 hot-fire test series. Propellant flow rate was measured using a coriolis mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup due to two-phase flow effects. Subsequent cold-flow testing demonstrated that the propellant manifolds must be adequately flushed in order for the coriolis flow meters to give accurate data. The coriolis flow meters were later shown to provide accurate steady-state data, but the turbine flow meter data should be used in transient phases of operation. Thrust was measured using three load cells in parallel, which also provides the capability to calculate thrust vector alignment. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes. All of these objectives were met with the RS-18 data and additional testing data from subsequent LO2/methane test programs in 2009 which included the first simulated-altitude pyrotechnic ignition demonstration of LO2/methane.

Melcher, John C., IV↗