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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 523 records · Page 29
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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 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 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.↗
NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗
NASA NTRS2004

Launch Vehicle Propulsion Parameter Design Multiple Selection Criteria

The optimization tool described herein addresses and emphasizes the use of computer tools to model a system and focuses on a concept development approach for a liquid hydrogen/liquid oxygen single-stage-to-orbit system, but more particularly the development of the optimized system using new techniques. This methodology uses new and innovative tools to run Monte Carlo simulations, genetic algorithm solvers, and statistical models in order to optimize a design concept. The concept launch vehicle and propulsion system were modeled and optimized to determine the best design for weight and cost by varying design and technology parameters. Uncertainty levels were applied using Monte Carlo Simulations and the model output was compared to the National Aeronautics and Space Administration Space Shuttle Main Engine. Several key conclusions are summarized here for the model results. First, the Gross Liftoff Weight and Dry Weight were 67% higher for the design case for minimization of Design, Development, Test and Evaluation cost when compared to the weights determined by the minimization of Gross Liftoff Weight case. In turn, the Design, Development, Test and Evaluation cost was 53% higher for optimized Gross Liftoff Weight case when compared to the cost determined by case for minimization of Design, Development, Test and Evaluation cost. Therefore, a 53% increase in Design, Development, Test and Evaluation cost results in a 67% reduction in Gross Liftoff Weight. Secondly, the tool outputs define the sensitivity of propulsion parameters, technology and cost factors and how these parameters differ when cost and weight are optimized separately. A key finding was that for a Space Shuttle Main Engine thrust level the oxidizer/fuel ratio of 6.6 resulted in the lowest Gross Liftoff Weight rather than at 5.2 for the maximum specific impulse, demonstrating the relationships between specific impulse, engine weight, tank volume and tank weight. Lastly, the optimum chamber pressure for Gross Liftoff Weight minimization was 2713 pounds per square inch as compared to 3162 for the Design, Development, Test and Evaluation cost optimization case. This chamber pressure range is close to 3000 pounds per square inch for the Space Shuttle Main Engine.

Shelton, Joey Dewayne↗
NASA NTRS2005

Launch Commit Criteria Monitoring Agent

The Spaceport Processing Systems Branch at NASA Kennedy Space Center has developed and deployed a software agent to monitor the Space Shuttle's ground processing telemetry stream. The application, the Launch Commit Criteria Monitoring Agent, increases situational awareness for system and hardware engineers during Shuttle launch countdown. The agent provides autonomous monitoring of the telemetry stream, automatically alerts system engineers when predefined criteria have been met, identifies limit warnings and violations of launch commit criteria, aids Shuttle engineers through troubleshooting procedures, and provides additional insight to verify appropriate troubleshooting of problems by contractors. The agent has successfully detected launch commit criteria warnings and violations on a simulated playback data stream. Efficiency and safety are improved through increased automation.

Semmel, Glenn S.↗
NASA NTRS1992

System for Anomaly and Failure Detection (SAFD) system development

This task specified developing the hardware and software necessary to implement the System for Anomaly and Failure Detection (SAFD) algorithm, developed under Technology Test Bed (TTB) Task 21, on the TTB engine stand. This effort involved building two units; one unit to be installed in the Block II Space Shuttle Main Engine (SSME) Hardware Simulation Lab (HSL) at Marshall Space Flight Center (MSFC), and one unit to be installed at the TTB engine stand. Rocketdyne personnel from the HSL performed the task. The SAFD algorithm was developed as an improvement over the current redline system used in the Space Shuttle Main Engine Controller (SSMEC). Simulation tests and execution against previous hot fire tests demonstrated that the SAFD algorithm can detect engine failure as much as tens of seconds before the redline system recognized the failure. Although the current algorithm only operates during steady state conditions (engine not throttling), work is underway to expand the algorithm to work during transient condition.

Oreilly, D.↗
NASA NTRS2024

Validation of Multiphase CFD Predictions of the SLS Launch Environment against Artemis I Flight Data

NASA’s Space Launch System (SLS) is powered by four Aerojet-Rocketdyne RS-25 engines, previously referred to as Space Shuttle Main Engines (SSMEs), with two RSRMV solid rocket boosters (SRBs) derived from the Shuttle booster as seen in Fig. 1. Ignition and the start transient of the SRBs, each of which generate 3.6 million pounds of thrust, create a series of large magnitude pressure waves separate from launch acoustics that have the potential to damage the vehicle if unmitigated. This portion of the SLS launch environment consists of igniter shock (IS), ignition overpressure (IOP), and duct overpressure (DOP).

T. Rivord↗
NASA NTRS2017

Next-Generation RS-25 Engines for the NASA Space Launch System

The utilization of heritage RS-25 engine, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway at NASA and the RS-25 engine provider, Aerojet Rocketdyne, to improve system affordability and eliminate obsolescence concerns. This paper describes how the achievement of these key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Ballard, Richard O.↗
NASA NTRS2015

SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture

A key constituent of the NASA Space Launch System (SLS) architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). This engine was selected largely due to the maturity and extensive experience gained through 30-plus years of service. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle and mounting it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration and operational details, there were also hardware upgrades needed. While the magnitude of effort is less than that needed to develop a new clean-sheet engine system, this paper describes some of the expected and unexpected challenges encountered to date on the path to the first flight of SLS.

Ballard, Richard O.↗
NASA NTRS1977

Tripropellant Engine Study

The feasibility of modifying the space shuttle main engine (SSME) for dual mode operation was investigated. Various high power cycle engine configurations derived from the SSME were configurations that will allow sequential burning of LOX/hydrocarbon and LOX/hydrogen were studied in order to identify concepts that make maximum use of SSME hardware and best satisfy the dual mode booster engine system application. Engine cycles were formulated for LOX/RP-1, LOX/CH4, and LOX/C3H8 propellants. Flow rates and operating cycles were established and the adaptability of the major components of the SSME was evaluated.

Wheeler, D. B.↗
NASA NTRS1978

Tripropellant engine study

The potential for converting the space shuttle main engine (SSME) to a dual-fuel, dual-mode engine using LOX/hydrocarbon propellants in mode 1 and LOX/H2 in mode 2 was examined. Various engine system concepts were formulated that included staged combustion and gas generator turbine power cycles, and LOX/RP-1, LOX/CH4, and LOX/C3H8 mode 1 propellants. Both oxidizer and fuel regenerative cooling were considered. All of the SSME major components were examined to determine their adaptability to the candidate dual-fuel engines.

Wheeler, D. B.↗
NASA NTRS1988

Application of advanced coating techniques to rocket engine components

The materials problem in the space shuttle main engine (SSME) is reviewed. Potential coatings and the method of their application for improved life of SSME components are discussed. A number of advanced coatings for turbine blade components and disks are being developed and tested in a multispecimen thermal fatigue fluidized bed facility at IIT Research Institute. This facility is capable of producing severe strains of the degree present in blades and disk components of the SSME. The potential coating systems and current efforts at IITRI being taken for life extension of the SSME components are summarized.

Verma, S. K.↗
NASA NTRS2003

Achieving Space Shuttle Abort-to-Orbit Using the Five-Segment Booster

The Five-Segment Booster design concept was evaluated by a team that determined the concept to be feasible and capable of achieving the desired abort-to-orbit capability when used in conjunction with increased Space Shuttle main engine throttle capability. The team (NASA Johnson Space Center, NASA Marshall Space Flight Center, ATK Thiokol Propulsion, United Space Alliance, Lockheed-Martin Space Systems, and Boeing) selected the concept that provided abort-to-orbit capability while: 1) minimizing Shuttle system impacts by maintaining the current interface requirements with the orbiter, external tank, and ground operation systems; 2) minimizing changes to the flight-proven design, materials, and processes of the current four-segment Shuttle booster; 3) maximizing use of existing booster hardware; and 4) taking advantage of demonstrated Shuttle main engine throttle capability. The added capability can also provide Shuttle mission planning flexibility. Additional performance could be used to: enable implementation of more desirable Shuttle safety improvements like crew escape, while maintaining current payload capability; compensate for off nominal performance in no-fail missions; and support missions to high altitudes and inclinations. This concept is a low-cost, low-risk approach to meeting Shuttle safety upgrade objectives. The Five-Segment Booster also has the potential to support future heavy-lift missions.

Craft, Joe↗
NASA NTRS1989

Space Logistics: Launch Capabilities

The current maximum launch capability for the United States are shown. The predicted Earth-to-orbit requirements for the United States are presented. Contrasting the two indicates the strong National need for a major increase in Earth-to-orbit lift capability. Approximate weights for planned payloads are shown. NASA is studying the following options to meet the need for a new heavy-lift capability by mid to late 1990's: (1) Shuttle-C for near term (include growth versions); and (2) the Advanced Lauching System (ALS) for the long term. The current baseline two-engine Shuttle-C has a 15 x 82 ft payload bay and an expected lift capability of 82,000 lb to Low Earth Orbit. Several options are being considered which have expanded diameter payload bays. A three-engine Shuttle-C with an expected lift of 145,000 lb to LEO is being evaluated as well. The Advanced Launch System (ALS) is a potential joint development between the Air Force and NASA. This program is focused toward long-term launch requirements, specifically beyond the year 2000. The basic approach is to develop a family of vehicles with the same high reliability as the Shuttle system, yet offering a much greater lift capability at a greatly reduced cost (per pound of payload). The ALS unmanned family of vehicles will provide a low end lift capability equivalent to Titan IV, and a high end lift capability greater than the Soviet Energia if requirements for such a high-end vehicle are defined.In conclusion, the planning of the next generation space telescope should not be constrained to the current launch vehicles. New vehicle designs will be driven by the needs of anticipated heavy users.

Furnas, Randall B.↗
NASA NTRS1987

Automatic mathematical modeling for space application

A methodology for automatic mathematical modeling is described. The major objective is to create a very friendly environment for engineers to design, maintain and verify their model and also automatically convert the mathematical model into FORTRAN code for conventional computation. A demonstration program was designed for modeling the Space Shuttle Main Engine simulation mathematical model called Propulsion System Automatic Modeling (PSAM). PSAM provides a very friendly and well organized environment for engineers to build a knowledge base for base equations and general information. PSAM contains an initial set of component process elements for the Space Shuttle Main Engine simulation and a questionnaire that allows the engineer to answer a set of questions to specify a particular model. PSAM is then able to automatically generate the model and the FORTRAN code. A future goal is to download the FORTRAN code to the VAX/VMS system for conventional computation.

Wang, Caroline K.↗