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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 397 records · Page 22

Analysis and test of insulated components for rotary engine

The direct-injection stratified-charge (DISC) rotary engine, while attractive for aviation applications due to its light weight, multifuel capability, and potentially low fuel consumption, has until now required a bulky and heavy liquid-cooling system. NASA-Lewis has undertaken the development of a cooling system-obviating, thermodynamically superior adiabatic rotary engine employing state-of-the-art thermal barrier coatings to thermally insulate engine components. The thermal barrier coating material for the cast aluminum, stainless steel, and ductile cast iron components was plasma-sprayed zirconia. DISC engine tests indicate effective thermal barrier-based heat loss reduction, but call for superior coefficient-of-thermal-expansion matching of materials and better tribological properties in the coatings used.

Badgley, Patrick R.↗

Software Estimates Costs of Testing Rocket Engines

Simulation-Based Cost Model (SiCM), a discrete event simulation developed in Extend , simulates pertinent aspects of the testing of rocket propulsion test articles for the purpose of estimating the costs of such testing during time intervals specified by its users. A user enters input data for control of simulations; information on the nature of, and activity in, a given testing project; and information on resources. Simulation objects are created on the basis of this input. Costs of the engineering-design, construction, and testing phases of a given project are estimated from numbers and labor rates of engineers and technicians employed in each phase, the duration of each phase; costs of materials used in each phase; and, for the testing phase, the rate of maintenance of the testing facility. The three main outputs of SiCM are (1) a curve, updated at each iteration of the simulation, that shows overall expenditures vs. time during the interval specified by the user; (2) a histogram of the total costs from all iterations of the simulation; and (3) table displaying means and variances of cumulative costs for each phase from all iterations. Other outputs include spending curves for each phase.

Smith, C. L.↗

Heat-transfer processes in air-cooled engine cylinders

From a consideration of heat-transfer theory, semi-empirical expressions are set up for the transfer of heat from the combustion gases to the cylinder of an air-cooled engine and from the cylinder to the cooling air. Simple equations for the average head and barrel temperatures as functions of the important engine and cooling variables are obtained from these expressions. The expressions involve a few empirical constants, which may be readily determined from engine tests. Numerical values for these constants were obtained from single-cylinder engine tests for cylinders of the Pratt & Whitney 1535 and 1340-h engines. The equations provide a means of calculating the effect of the various engine and cooling variables on the cylinder temperatures and also of correlating the results of engine cooling tests. An example is given of the application of the equations to the correlation of cooling-test data obtained in flight.

Pinkel, Benjamin↗

NASA Glenn Research Center, Propulsion Systems Laboratory: Plan to Measure Engine Core Flow Water Vapor Content

This presentation will be made at the 92nd AIAA Turbine Engine Testing Working Group (TETWoG), a semi-annual technical meeting of turbine engine testing professionals. The objective is to describe an effort by NASA to measure the water vapor content on the core airflow in a full scale turbine engine ice crystal icing test and to open a discussion with colleagues how to accurately conduct the measurement based on any previous collective experience with the procedure, instruments and nature of engine icing testing within the group. The presentation lays out the schematics of the location in the flow path from which the sample will be drawn, the plumbing to get it from the engine flow path to the sensor and several different water vapor measurement technologies that will be used: Tunable diode laser and infrared spectroscopy.

core flow humidity measurement↗

Hyper-X Research Vehicle (HXRV) Experimental Aerodynamics Test Program Overview

This paper provides an overview of the experimental aerodynamics test program to ensure mission success for the autonomous flight of the Hyper-X Research Vehicle (HXRV). The HXRV is a 12-ft long, 2700 lb lifting body technology demonstrator designed to flight demonstrate for the first time a fully airframe integrated scramjet propulsion system. Three flights are currently planned, two at Mach 7 and one at Mach 10, beginning in the fall of 2000. The research vehicles will be boosted to the prescribed scramjet engine test point where they will separate from the booster, stabilize. and initiate engine test. Following 5+ seconds of powered flight and 15 seconds of cowl-open tares, the cowl will close and the vehicle will fly a controlled deceleration trajectory which includes numerous control doublets for in-flight aerodynamic parameter identification. This paper reviews the preflight testing activities, wind tunnel models, test rationale. risk reduction activities, and sample results from wind tunnel tests supporting the flight trajectory of the HXRV from hypersonic engine test point through subsonic flight termination.

Holland, Scott D.↗

Hyper-X Research Vehicle (HXRV) Experimental Aerodynamics Test Program Overview

This paper provides an overview of the experimental aerodynamics test program to ensure mission success for the autonomous flight of the Hyper-X Research Vehicle (HXRV). The HXRV is a 12-ft long, 2700 lb lifting body technology demonstrator designed to flight demonstrate for the first time a fully airframe integrated scramjet propulsion system. Three flights are currently planned, two at Mach 7 and one at Mach 10, beginning in the fall of 2000. The research vehicles will be boosted to the prescribed scramjet engine test point where they will separate from the booster, stabilize, and initiate engine test. Following 5+ seconds of powered flight and 15 seconds of cow-open tares, the cowl will close and the vehicle will fly a controlled deceleration trajectory which includes numerous control doublets for in-flight aerodynamic parameter identification. This paper reviews the preflight testing activities, wind tunnel models, test rationale, risk reduction activities, and sample results from wind tunnel tests supporting the flight trajectory of the HXRV from hypersonic engine test point through subsonic flight termination.

Holland, Scott D.↗

Drive Rig Mufflers for Model Scale Engine Acoustic Testing

Testing of air breathing propulsion systems in the 9x15 foot wind tunnel at NASA Glenn Research Center depends on compressed air turbines for power. The drive rig turbines exhaust directly to the wind tunnel test section, and have been found to produce significant unwanted noise that reduces the quality of the acoustic measurements of the model being tested. In order to mitigate this acoustic contamination, a muffler can be attached downstream of the drive rig turbine. The modern engine designs currently being tested produce much less noise than traditional engines, and consequently a lower noise floor is required of the facility. An acoustic test of a muffler designed to mitigate this extraneous noise is presented, and a noise reduction of 8 dB between 700 Hz and 20 kHz was documented, significantly improving the quality of acoustic measurements in the facility.

Stephens, David↗

Boosted performance of a compression-ignition engine with a displaced piston

Performance tests were made using a rectangular displacer arranged so that the combustion air was forced through equal passages at either end of the displacer into the vertical-disk combustion chamber of a single-cylinder, four-stroke-cycle compression-ignition test engine. After making tests to determine optimum displacer height, shape, and fuel-spray arrangement, engine-performance tests were made at 1,500 and 2,000 r.p.m. for a range of boost pressures from 0 to 20 inches of mercury and for maximum cylinder pressures up to 1,150 pounds per square inch. The engine operation for boosted conditions was very smooth, there being no combustion shock even at the highest maximum cylinder pressures. Indicated mean effective pressures of 240 pounds per square inch for fuel consumptions of 0.39 pound per horsepower-hour have been readily reproduced during routine testing at 2,000 r.p.m. at a boost pressure of 20 inches of mercury.

Moore, Charles S↗

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Unsteady Analyses and Risk Assessment - Part 2

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Design Support of the feasibility of operating conditions and procedures is critical in such cases due to the possibility of startup/shutdown transients, moving shock structures, unsteady shock-boundary layer interactions and engine and diffuser unstart modes that can result in catastrophic failure. Analyses of such systems is difficult due to resolution requirements needed to accurately capture moving shock structures, shock-boundary layer interactions, two-phase flow regimes and engine unstart modes. In a companion paper, we will demonstrate with the use of CFD, steady analyses advanced capability to evaluate supersonic diffuser and steam ejector performance in the sub-scale A-3 facility. In this paper we will address transient issues with the operation of the facility especially at startup and shutdown, and assess risks related to afterburning due to the interaction of a fuel rich plume with oxygen that is a by-product of the steam ejectors. The primary areas that will be addressed in this paper are: (1) analyses of unstart modes due to flow transients especially during startup/ignition, (2) engine safety during the shutdown process (3) interaction of steam ejectors with the primary plume i.e. flow transients as well as probability of afterburning. In this abstract we discuss unsteady analyses of the engine shutdown process. However, the final paper will include analyses of a staged startup, drawdown of the engine test cell pressure, and risk assessment of potential afterburning in the facility. Unsteady simulations have been carried out to study the engine shutdown process in the facility and understand the physics behind the interactions between the steam ejectors, the test cell and the supersonic diffuser. As a first approximation, to understand the dominant unsteady mechanisms in the engine test cell and the supersonic diffuser, the turning duct in the facility was removed. As the engine loses power a rarefaction wave travels downstream that disrupts the shock cell structure in the supersonic diffuser. Flow from the test cell is seen to expand into the supersonic diffuser section and re-pressurizes the area around the nozzle along with a upstream traveling compression wave that emanates from near the first stage ejectors. Flow from the first stage ejector expands to the center of the duct and a new shock train is formed between the first and second stage ejectors. Both stage ejectors keep the facility pressurized and prevent any large amplitude pressure fluctuations from affecting the engine nozzle. The resultant pressure loads the nozzle experiences in the shutdown process are small.

Ahuja, Vineet↗

An integrated knowledge system for wind tunnel testing - Project Engineers' Intelligent Assistant

The Project Engineers' Intelligent Assistant (PEIA) is an integrated knowledge system developed using artificial intelligence technology, including hypertext, expert systems, and dynamic user interfaces. This system integrates documents, engineering codes, databases, and knowledge from domain experts into an enriched hypermedia environment and was designed to assist project engineers in planning and conducting wind tunnel tests. PEIA is a modular system which consists of an intelligent user-interface, seven modules and an integrated tool facility. Hypermedia technology is discussed and the seven PEIA modules are described. System maintenance and updating is very easy due to the modular structure and the integrated tool facility provides user access to commercial software shells for documentation, reporting, or database updating. PEIA is expected to provide project engineers with technical information, increase efficiency and productivity, and provide a realistic tool for personnel training.

Lo, Ching F.↗

USB environment measurements based on full-scale static engine ground tests

Flow turning parameters, static pressures, surface temperatures, surface fluctuating pressures and acceleration levels were measured in the environment of a full-scale upper surface blowing (USB) propulsive-lift test configuration. The test components included a flightworthy CF6-50D engine, nacelle and USB flap assembly utilized in conjunction with ground verification testing of the USAF YC-14 Advanced Medium STOL Transport propulsion system. Results, based on a preliminary analysis of the data, generally show reasonable agreement with predicted levels based on model data. However, additional detailed analysis is required to confirm the preliminary evaluation, to help delineate certain discrepancies with model data and to establish a basis for future flight test comparisons.

Sussman, M. B.↗

USB environment measurements based on full-scale static engine ground tests

Flow turning parameters, static pressures, surface temperatures, surface fluctuating pressures and acceleration levels were measured in the environment of a full-scale upper surface blowing (USB) propulsive lift test configuration. The test components included a flightworthy CF6-50D engine, nacelle, and USB flap assembly utilized in conjunction with ground verification testing of the USAF YC-14 Advanced Medium STOL Transport propulsion system. Results, based on a preliminary analysis of the data, generally show reasonable agreement with predicted levels based on model data. However, additional detailed analysis is required to confirm the preliminary evaluation, to help delineate certain discrepancies with model data, and to establish a basis for future flight test comparisons.

Sussman, M. B.↗

Inverse problems in the design, modeling and testing of engineering systems

Formulations, classification, areas of application, and approaches to solving different inverse problems are considered for the design of structures, modeling, and experimental data processing. Problems in the practical implementation of theoretical-experimental methods based on solving inverse problems are analyzed in order to identify mathematical models of physical processes, aid in input data preparation for design parameter optimization, help in design parameter optimization itself, and to model experiments, large-scale tests, and real tests of engineering systems.

Alifanov, Oleg M.↗

ISHM Anomaly Lexicon for Rocket Test

Integrated Systems Health Management (ISHM) is a comprehensive capability. An ISHM system must detect anomalies, identify causes of such anomalies, predict future anomalies, help identify consequences of anomalies for example, suggested mitigation steps. The system should also provide users with appropriate navigation tools to facilitate the flow of information into and out of the ISHM system. Central to the ability of the ISHM to detect anomalies is a clearly defined catalog of anomalies. Further, this lexicon of anomalies must be organized in ways that make it accessible to a suite of tools used to manage the data, information and knowledge (DIaK) associated with a system. In particular, it is critical to ensure that there is optimal mapping between target anomalies and the algorithms associated with their detection. During the early development of our ISHM architecture and approach, it became clear that a lexicon of anomalies would be important to the development of critical anomaly detection algorithms. In our work in the rocket engine test environment at John C. Stennis Space Center, we have access to a repository of discrepancy reports (DRs) that are generated in response to squawks identified during post-test data analysis. The DR is the tool used to document anomalies and the methods used to resolve the issue. These DRs have been generated for many different tests and for all test stands. The result is that they represent a comprehensive summary of the anomalies associated with rocket engine testing. Fig. 1 illustrates some of the data that can be extracted from a DR. Such information includes affected transducer channels, narrative description of the observed anomaly, and the steps used to correct the problem. The primary goal of the anomaly lexicon development efforts we have undertaken is to create a lexicon that could be used in support of an associated health assessment database system (HADS) co-development effort. There are a number of significant byproducts of the anomaly lexicon compilation effort. For example, (1) Allows determination of the frequency distribution of anomalies to help identify those with the potential for high return on investment if included in automated detection as part of an ISHM system, (2) Availability of a regular lexicon could provide the base anomaly name choices to help maintain consistency in the DR collection process, and (3) Although developed for the rocket engine test environment, most of the anomalies are not specific to rocket testing, and thus can be reused in other applications.

Schmalzel, John L.↗

Modeling Potential Carbon Monoxide Exposure Due to Operation of a Major Rocket Engine Altitude Test Facility Using Computational Fluid Dynamics

This viewgraph presentation reviews computational fluid dynamics as a tool for modelling the dispersion of carbon monoxide at the Stennis Space Center's A3 Test Stand. The contents include: 1) Constellation Program; 2) Constellation Launch Vehicles; 3) J2X Engine; 4) A-3 Test Stand; 5) Chemical Steam Generators; 6) Emission Estimates; 7) Located in Existing Test Complex; 8) Computational Fluid Dynamics; 9) Computational Tools; 10) CO Modeling; 11) CO Model results; and 12) Next steps.

Blotzer, Michael J.↗

Space Shuttle Orbital Maneuvering Subsystem (OMS) Engine Propellant Leakage Ball-Valve Shaft Seals

Evidence of propellant leakage across ball-valve shaft seals has been noted during the disassembly of five flight engines and one test engine at the NASA Lyndon B. Johnson Space Center, White Sands Test Facility. Based on data collected during the disassembly of these five engines, the consequences of propellant leakage across the ball-valve shaft seals can be divided into four primary areas of concern: Damage to the ball-valve pinion shafts, damage to sleeved bearings inside the ball-valve and actuator assemblies, degradation of the synthetic rubber o-rings used in the actuator assemblies, and corrosion and degradation to the interior of the actuator assemblies. The exact time at which leakage across the ball-valve shaft seals occurs has not been determined, however, the leakage most likely occurs during engine firings when, depending on the specification used, ball-valve cavity pressures range as high as 453 to 550 psia. This potential pressure range for the ball-valve cavities greatly exceeds the acceptance leakage test pressure of 332 psia. Since redesign and replacement of the ball-valve shaft seals is unlikely, the near term solution to prevent damage that occurs from shaft-seal leakage is to implement a routine overhaul and maintenance program for engines in the fleet. Recommended repair, verification, and possible preventative maintenance measures are discussed in the paper.

Lueders, Kathy↗

Energy efficient engine combustor test hardware detailed design report

The combustor for the Energy Efficient Engine is an annular, two-zone component. As designed, it either meets or exceeds all program goals for performance, safety, durability, and emissions, with the exception of oxides of nitrogen. When compared to the configuration investigated under the NASA-sponsored Experimental Clean Combustor Program, which was used as a basis for design, the Energy Efficient Engine combustor component has several technology advancements. The prediffuser section is designed with short, strutless, curved-walls to provide a uniform inlet airflow profile. Emissions control is achieved by a two-zone combustor that utilizes two types of fuel injectors to improve fuel atomization for more complete combustion. The combustor liners are a segmented configuration to meet the durability requirements at the high combustor operating pressures and temperatures. Liner cooling is accomplished with a counter-parallel FINWALL technique, which provides more effective heat transfer with less coolant.

Zeisser, M. H.↗