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At least 487 records · Page 27

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NASA NTRS2010

Coaxial Propellant Injectors With Faceplate Annulus Control

An improved design concept for coaxial propellant injectors for a rocket engine (or perhaps for a non-rocket combustion chamber) offers advantages of greater robustness, less complexity, fewer parts, lower cost, and less bulk, relative to prior injectors of equivalent functionality. This design concept is particularly well suited to small, tight-tolerance injectors, for which prior designs are not suitable because the practical implementation of those designs entails very high costs and difficulty in adhering to the tolerances.

Horn, Mark D.↗

NASA NTRS2013

Regeneratively Cooled Porous Media Jacket

The fluid and heat transfer theory for regenerative cooling of a rocket combustion chamber with a porous media coolant jacket is presented. This model is used to design a regeneratively cooled rocket or other high temperature engine cooling jacket. Cooling jackets comprising impermeable inner and outer walls, and porous media channels are disclosed. Also disclosed are porous media coolant jackets with additional structures designed to transfer heat directly from the inner wall to the outer wall, and structures designed to direct movement of the coolant fluid from the inner wall to the outer wall. Methods of making such jackets are also disclosed.

Mungas, Greg↗

NASA NTRS1972

Design and evaluation of an oxidant-fuel-ratio-zoned rocket injector for high performance and ablative engine compatibility

A method for temperature control of the combustion gases in the peripheral zone of a rocket combustor which would reduce ablative throat erosion, prevent melting of zirconia throat inserts, and maintain high combustion performance is discussed. Included are techniques for analyzing and predicting zoned injector performance, as well as the philosophy and method for accomplishing an optimum compromise between high performance and reduced effective gas temperature. The experimental work was done with a 1000-lbf rocket engine which used as propellants N2O4 and a blend of 50-percent N2H4 and 50-percent UDMH at 100-psia chamber pressure and an overall O/F of 2.0. The method selected to provide temperature control was to use 30 percent of the propellant to form a peripheral zone of combustion gases at an O/F of 1.31 and 2700 K. The remaining 70 percent of the propellant in the core was at an O/F of 2.45 to keep the overall O/F at 2.0.

Winter, J. M.↗

NASA NTRS2000

THRSTER: A Three-Stream Ejector Ramjet Analysis and Design Tool

An engineering tool for analyzing ejectors in rocket based combined cycle (RBCC) engines has been developed. A key technology for multi-cycle RBCC propulsion systems is the ejector which functions as the compression stage of the ejector ramjet cycle. The THRee STream Ejector Ramjet analysis tool was developed to analyze the complex aerothermodynamic and combustion processes that occur in this device. The formulated model consists of three quasi-one-dimensional streams, one each for the ejector primary flow, the secondary flow, and the mixed region. The model space marches through the mixer, combustor, and nozzle to evaluate the solution along the engine. In its present form, the model is intended for an analysis mode in which the diffusion rates of the primary and secondary into the mixed stream are stipulated. The model offers the ability to analyze the highly two-dimensional ejector flowfield while still benefits from the simplicity and speed of an engineering tool. To validate the developed code, wall static pressure measurements from the Penn-State and NASA-ART RBCC experiments were used to compare with the results generated by the code. The calculated solutions were generally found to have satisfactory agreement with the pressure measurements along the engines, although further modeling effort may be required when a strong shock train is formed at the rocket exhaust. The range of parameters in which the code would generate valid results are presented and discussed.

Chue, R. S.↗

NASA NTRS2000

THRSTER: A THRee-STream Ejector Ramjet Analysis and Design Tool

Chue, R. S.↗

NASA NTRS2002

A Three-Dimensional Parallel Time-Accurate Turbopump Simulation Procedure Using Overset Grid System

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and nonuniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation 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 the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability are presented along with the performance of parallel versions of the code.

Kiris, Cetin↗

NASA NTRS2001

Time-Dependent Simulations of Turbopump Flows

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort will provide developers with information such as transient flow phenomena at start up, impact of non-uniform inflows, system vibration and impact on the structure. In the proposed paper, the progress toward the capability of complete simulation 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 the hybrid MPI/Open-MP and MLP versions of the INS3D code. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Time-accuracy of the scheme has been evaluated with simple test cases. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kris, Cetin C.↗

NASA NTRS2001

A Three Dimensional Parallel Time Accurate Turbopump Simulation Procedure Using Overset Grid Systems

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and non-uniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation 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 the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kiris, Cetin↗

NASA NTRS1995

Centrifugal and Axial Pump Design and Off-Design Performance Prediction

A meanline pump-flow modeling method has been developed to provide a fast capability for modeling pumps of cryogenic rocket engines. Based on this method, a meanline pump-flow code PUMPA was written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The design-point rotor efficiency and slip factors are obtained from empirical correlations to rotor-specific speed and geometry. The pump code can model axial, inducer, mixed-flow, and centrifugal pumps and can model multistage pumps in series. The rapid input setup and computer run time for this meanline pump flow code make it an effective analysis and conceptual design tool. The map-generation capabilities of the code provide the information needed for interfacing with a rocket engine system modeling code. The off-design and multistage modeling capabilities of PUMPA permit the user to do parametric design space exploration of candidate pump configurations and to provide head-flow maps for engine system evaluation.

Veres, Joseph P.↗

NASA NTRS1985

Two-dimensional kinetics computer program for orbit transfer vehicles

Future Orbit Transfer Vehicles (OTV) presently under consideration require rocket engines delivering a high specific impulse. This high performance can be obtained with large area ratio thrust chambers using oxygen with either hydrogen or hydrocarbon fuels. In the projected nozzles, the combustion products are expanded to low pressure and temperature levels at high Mach number, a domain which has not been experienced with existing rocket engines. In order to assist in the design and evaluation of OTV engines, modifications have recently been incorporated in the Two-Dimensional-Kinetics (TDK) computer program. These modifications include the treatment of shock waves induced by the wall curvature, and shocks which are attached to the wall. The reflection of a shock wave at the flow axis is also treated in an appropriate manner and multiple shock reflections are allowed. A Boundary Layer Module (BLM) has also been incorporated into the TDK computer program in order to provide an automated treatment of the rigorous JANNAF rocket engine performance prediction procedure.

Nickerson, G. R.↗

NASA NTRS2006

Validation of a Pressure-Based Combustion Simulation Tool Using a Single Element Injector Test Problem

The traditional design and analysis practice for advanced propulsion systems, particularly chemical rocket engines, relies heavily on expensive full-scale prototype development and testing. Over the past decade, use of high-fidelity analysis and design tools such as CFD early in the product development cycle has been identified as one way to alleviate testing costs and to develop these devices better, faster and cheaper. Increased emphasis is being placed on developing and applying CFD models to simulate the flow field environments and performance of advanced propulsion systems. This necessitates the development of next generation computational tools which can be used effectively and reliably in a design environment by non-CFD specialists. A computational tool, called Loci-STREAM is being developed for this purpose. It is a pressure-based, Reynolds-averaged Navier-Stokes (RANS) solver for generalized unstructured grids, which is designed to handle all-speed flows (incompressible to hypersonic) and is particularly suitable for solving multi-species flow in fixed-frame combustion devices. Loci-STREAM integrates proven numerical methods for generalized grids and state-of-the-art physical models in a novel rule-based programming framework called Loci which allows: (a) seamless integration of multidisciplinary physics in a unified manner, and (b) automatic handling of massively parallel computing. The objective of the ongoing work is to develop a robust simulation capability for combustion problems in rocket engines. As an initial step towards validating this capability, a model problem is investigated in the present study which involves a gaseous oxygen/gaseous hydrogen (GO2/GH2) shear coaxial single element injector, for which experimental data are available. The sensitivity of the computed solutions to grid density, grid distribution, different turbulence models, and different near-wall treatments is investigated. A refined grid, which is clustered in the vicinity of the solid walls as well as the flame, is used to obtain a steady state solution which may be considered as the best solution attainable with the steady-state RANS methodology. From a design point of view, quick turnaround times are desirable; with this in mind, coarser grids are also employed and the resulting solutions are evaluated with respect to the fine grid solution.

Thakur, Siddarth↗

NASA NTRS2006

Engine System Model Development for Nuclear Thermal Propulsion

In order to design, analyze, and evaluate conceptual Nuclear Thermal Propulsion (NTP) engine systems, an improved NTP design and analysis tool has been developed. The NTP tool utilizes the Rocket Engine Transient Simulation (ROCETS) system tool and many of the routines from the Enabler reactor model found in Nuclear Engine System Simulation (NESS). Improved non-nuclear component models and an external shield model were added to the tool. With the addition of a nearly complete system reliability model, the tool will provide performance, sizing, and reliability data for NERVA-Derived NTP engine systems. A new detailed reactor model is also being developed and will replace Enabler. The new model will allow more flexibility in reactor geometry and include detailed thermal hydraulics and neutronics models. A description of the reactor, component, and reliability models is provided. Another key feature of the modeling process is the use of comprehensive spreadsheets for each engine case. The spreadsheets include individual worksheets for each subsystem with data, plots, and scaled figures, making the output very useful to each engineering discipline. Sample performance and sizing results with the Enabler reactor model are provided including sensitivities. Before selecting an engine design, all figures of merit must be considered including the overall impacts on the vehicle and mission. Evaluations based on key figures of merit of these results and results with the new reactor model will be performed. The impacts of clustering and external shielding will also be addressed. Over time, the reactor model will be upgraded to design and analyze other NTP concepts with CERMET and carbide fuel cores.

Nelson, Karl W.↗

NASA NTRS1990

Prediction of the Thrust Performance and the Flowfield of Liquid Rocket Engines

In an effort to improve the current solutions in the design and analysis of liquid propulsive engines, a computational fluid dynamics (CFD) model capable of calculating the reacting flows from the combustion chamber, through the nozzle to the external plume, was developed. The Space Shuttle Main Engine (SSME) fired at sea level, was investigated as a sample case. The CFD model, FDNS, is a pressure based, non-staggered grid, viscous/inviscid, ideal gas/real gas, reactive code. An adaptive upwinding differencing scheme is employed for the spatial discretization. The upwind scheme is based on fourth order central differencing with fourth order damping for smooth regions, and second order central differencing with second order damping for shock capturing. It is equipped with a CHMQGM equilibrium chemistry algorithm and a PARASOL finite rate chemistry algorithm using the point implicit method. The computed flow results and performance compared well with those of other standard codes and engine hot fire test data. In addition, the transient nozzle flowfield calculation was also performed to demonstrate the ability of FDNS in capturing the flow separation during the startup process.

Wang, T.-S.↗

NASA NTRS2010

A History of Welding on the Space Shuttle Main Engine (1975 to 2010)

The Space Shuttle Main Engine (SSME) is a high performance, throttleable, liquid hydrogen fueled rocket engine. High thrust and specific impulse (Isp) are achieved through a staged combustion engine cycle, combined with high combustion pressure (approx.3000psi) generated by the two-stage pump and combustion process. The SSME is continuously throttleable from 67% to 109% of design thrust level. The design criteria for this engine maximize performance and weight, resulting in a 7,800 pound rocket engine that produces over a half million pounds of thrust in vacuum with a specific impulse of 452/sec. It is the most reliable rocket engine in the world, accumulating over one million seconds of hot-fire time and achieving 100% flight success in the Space Shuttle program. A rocket engine with the unique combination of high reliability, performance, and reusability comes at the expense of manufacturing simplicity. Several innovative design features and fabrication techniques are unique to this engine. This is as true for welding as any other manufacturing process. For many of the weld joints it seemed mean cheating physics and metallurgy to meet the requirements. This paper will present a history of the welding used to produce the world s highest performance throttleable rocket engine.

Zimmerman, Frank R.↗

NASA NTRS1963

HOW MUCH FUTURE FOR ELECTRIC PROPULSION

Low powerplant weight and elimination of waste heat in order to provide adequate endurance are the primary aims of electric propulsion system design

ROCKET ENGINE↗

NASA NTRS2015

Design and Fabrication Development of J-2X Engine Metallic Nozzle Extension

Maximized rocket engine performance is in part derived from expanding combustion gasses through the rocket nozzle. For upper stage engines the nozzles can be quite large. On the J-2X engine, an uncooled extension of a regeneratively cooled nozzle is used to expand the combustion gasses to a targeted exit pressure which is defined by an altitude for the desired maximum performance. Creating a J-2X nozzle extension capable of surviving the loads of test and flight environments while meeting engine system performance requirements required development of new processes and facilities. Meeting the challenges of the development resulted in concurrent J-2X nozzle extension design and fabrication. This paper describes how some of the design and fabrication challenges were resolved.

Kopicz, C.↗

NASA NTRS2019

Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component Applications

NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. 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 channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.

Katsarelis, Colton↗

NASA NTRS1990

A highly durable injector faceplate design concept for O2/H2 propellants

Two different O2/H2 injector faceplate designs were used in a test bed rocket engine at the NASA Lewis Research Center facility. This test bed was operated in a pulsing mode to evaluate thrust chamber wall materials and coatings. Degradation of the sintered mesh injector face plates resulted in the substitution of a photoetched diffusion-bonded platelet faceplate. This faceplate accumulated over 4200 thermal cycles without damage or degradation. Prior testing for a total of 17,446 cycles required 19 sintered mesh faceplates. This average of 918 cycles per unit showed the diffusion bonded faceplate to have a thermal cycle capability ranging from 150 to 500 percent of that of the sintered wire unit. The test data also showed that the diffusion-bonded faceplate provided a more uniform flow of gaseous H2 through its discrete and uniformly spaced propellant orifices resulting in enhanced face cooling (no local hot spots) and increased performance. The injector faceplate designs are described and the results of the injector comparison test data are presented.

Mueggenburg, H. H.↗