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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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NASA NTRS2013

Software Tools to Support the Assessment of System Health

This presentation provides an overview of three software tools that were developed by the NASA Glenn Research Center to support the assessment of system health: the Propulsion Diagnostic Method Evaluation Strategy (ProDIMES), the Systematic Sensor Selection Strategy (S4), and the Extended Testability Analysis (ETA) tool. Originally developed to support specific NASA projects in aeronautics and space, these software tools are currently available to U.S. citizens through the NASA Glenn Software Catalog. The ProDiMES software tool was developed to support a uniform comparison of propulsion gas path diagnostic methods. Methods published in the open literature are typically applied to dissimilar platforms with different levels of complexity. They often address different diagnostic problems and use inconsistent metrics for evaluating performance. As a result, it is difficult to perform a one ]to ]one comparison of the various diagnostic methods. ProDIMES solves this problem by serving as a theme problem to aid in propulsion gas path diagnostic technology development and evaluation. The overall goal is to provide a tool that will serve as an industry standard, and will truly facilitate the development and evaluation of significant Engine Health Management (EHM) capabilities. ProDiMES has been developed under a collaborative project of The Technical Cooperation Program (TTCP) based on feedback provided by individuals within the aircraft engine health management community. The S4 software tool provides a framework that supports the optimal selection of sensors for health management assessments. S4 is structured to accommodate user ]defined applications, diagnostic systems, search techniques, and system requirements/constraints. One or more sensor suites that maximize this performance while meeting other user ]defined system requirements that are presumed to exist. S4 provides a systematic approach for evaluating combinations of sensors to determine the set or sets of sensors that optimally meet the performance goals and the constraints. It identifies optimal sensor suite solutions by utilizing a merit (i.e., cost) function with one of several available optimization approaches. As part of its analysis, S4 can expose fault conditions that are difficult to diagnose due to an incomplete diagnostic philosophy and/or a lack of sensors. S4 was originally developed and applied to liquid rocket engines. It was subsequently used to study the optimized selection of sensors for a simulation ]based aircraft engine diagnostic system. The ETA Tool is a software ]based analysis tool that augments the testability analysis and reporting capabilities of a commercial ]off ]the ]shelf (COTS) package. An initial diagnostic assessment is performed by the COTS software using a user ]developed, qualitative, directed ]graph model of the system being analyzed. The ETA Tool accesses system design information captured within the model and the associated testability analysis output to create a series of six reports for various system engineering needs. These reports are highlighted in the presentation. The ETA Tool was developed by NASA to support the verification of fault management requirements early in the Launch Vehicle process. Due to their early development during the design process, the TEAMS ]based diagnostic model and the ETA Tool were able to positively influence the system design by highlighting gaps in failure detection, fault isolation, and failure recovery.

Melcher, Kevin J.↗
NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

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. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has 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.

Paul Gradl↗
NASA NTRS1972

Design criteria monograph for high-load high-speed rolling-contact bearings

Monograph was published which summarizes and systematically orders large body of successful techniques and practices developed for design of liquid rocket engine turbopump bearings. Document was written to organize and present significant experience and knowledge accumulated by NASA in development and operational programs.

Source record↗
NASA NTRS1972

Design criteria monograph on turbopump inducers

State of the art and design criteria for liquid rocket engine turbopump inducers are summarized for optimal fabrication. Design criteria optimize hydrodynamic parameters to obtain highest suction specific speed without violating structural and mechanical constraints.

Source record↗
NASA NTRS1972

Liquid rocket performance computer model with distributed energy release

Development of a computer program for analyzing the effects of bipropellant spray combustion processes on liquid rocket performance is described and discussed. The distributed energy release (DER) computer program was designed to become part of the JANNAF liquid rocket performance evaluation methodology and to account for performance losses associated with the propellant combustion processes, e.g., incomplete spray gasification, imperfect mixing between sprays and their reacting vapors, residual mixture ratio striations in the flow, and two-phase flow effects. The DER computer program begins by initializing the combustion field at the injection end of a conventional liquid rocket engine, based on injector and chamber design detail, and on propellant and combustion gas properties. It analyzes bipropellant combustion, proceeding stepwise down the chamber from those initial conditions through the nozzle throat.

Combs, L. P.↗
NASA NTRS1972

Life prediction of expulsion bladders through fatigue test and fold strain analysis.

Consideration of the problem of reducing the probability of mechanical failure of bladder systems used for the expulsion of propellants into liquid rocket engines. It is shown that individual local folds in collapsing bladders can be classified into single and double folds, specifiable by nondimensional geometrical parameters which directly define the maximum strains at these folds. From these maximum strains the number of collapse/inflation cycles to failure can be obtained from low-cycle fatigue data experimentally determined for the bladder material of interest. Cycle life data are presented in terms of true maximum strain for four metals, two plastics, and two elastomers. It is found that double folds give rise to much more severe folding strains than do simple folds.

Chu, H. N.↗
NASA NTRS1972

Dynamics of cavitating cascades

Brief accounts of the theoretical research conducted on the unsteady cavitation characteristics of liquid rocket engine turbopumps are reported. The objective is to produce estimates of the cavitation compliance and other unsteady characteristics which could then be used in analysis of the pogo instability. Blade cavitation is the particular pheonomenon which is investigated and line arized free streamline methods were employed in both quasistatic and complete dynamic cascade analyses of the unsteady flow. The simpler quasistatic analysis was applied to particular turbopumps but yielded values of compliances significantly smaller than those indirectly obtained from experiments. Reasons for this discrepancy are discussed. The complete dynamic analysis presents a new problem in fundamental hydrodynamics and, though the basic solution is presented, numerical results have not as yet been obtained.

Acosta, A. J.↗
NASA NTRS1974

Noncircular orifice holes and advanced fabrication techniques for liquid rocket injectors. Phase 3: Analytical and cold-flow experimental evaluation of rectangular concentric tube injector elements for gas/liquid application. Phase 4: Analytical and experimental evaluation of noncircular injector elements for gas/liquid and liquid/liquid application

Results are presented of a cold-flow and hot-fire experimental study of the mixing and atomization characteristics of injector elements incorporating noncircular orifices. Both liquid/liquid and gas/liquid element types are discussed. Unlike doublet and triplet elements (circular orifices only) were investigated for the liquid/liquid case while concentric tube elements were investigated for the gas/liquid case. It is concluded that noncircular shape can be employed to significant advantage in injector design for liquid rocket engines.

Mchale, R. M.↗
NASA NTRS1974

Noncircular Orifice Holes and Advanced Fabrication Techniques for Liquid Rocket Injectors (Phases 1, 2, 3, and 4)

A comprehensive summary of the results of a cold-flow and hot-fire experimental study of the mixing and atomization characteristics of injector elements incorporating noncircular orifices is presented. Both liquid/liquid and gas/liquid element types are discussed. Unlike doublet and triplet elements (circular orifices only) were investigated for the liquid/liquid case while concentric tube elements were investigated for the gas/liquid case. It is concluded that noncircular shape can be employed to significant advantage in injector design for liquid rocket engines.

Mchale, R. M.↗
NASA NTRS1973

Introduction to the Space Transportation System

A new space transportation concept which is consistent with the need for more cost effective space operations has been developed. The major element of the Space Transportation System (STS) is the Space Shuttle. The rest of the system consists of a propulsive stage which can be carried within the space shuttle to obtain higher energy orbits. The final form of this propulsion stage will be called the Space Tug. A third important element, which is not actually a part of the STS since it has no propulsive capacity, is the Space Laboratory. The major element of the Space Shuttle is an aircraft-like orbiter which contains the crew, the cargo, and the liquid rocket engines in the rear.

Wilson, R. G.↗
NASA NTRS1975

Unsteady flow in cavitating turbopumps

Unsteady flow in a cavitating axial inducer pump is analyzed with the help of a simple two-dimensional cascade model. This problem was motivated by a desire to study the effect of unsteady cavitation on the so-called POGO instability in the operation of liquid rocket engines. Here, an important feature is a closed loop coupling between several different modes of oscillation, one of which is due to the basic unsteady characteristics of the cavitation itself. The approaching and leaving flow velocities up- and downstream of the inducer oscillate, and the cavity-blade system participates dynamically with the basic pulsating flow. In the present work, attention is focused on finding a transfer matrix that relates the set of upstream variables to those downstream. This quantity, which is essentially equivalent to cavitation compliance in the quasi-static analyses, is found to be complex and frequency dependent.

Kim, J. H.↗