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At least 55 records · Page 3

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NASA NTRS1993

Apparatus for testing high pressure injector elements

An apparatus for testing and evaluating the spray pattern of high pressure fuel injector elements for use in supplying fuel to combustion engines is presented. Prior art fuel injector elements were normally tested by use of low pressure apparatuses which did not provide a purge to prevent mist from obscuring the injector element or to prevent frosting of the view windows; could utilize only one fluid during each test; and had their viewing ports positioned one hundred eighty (180 deg) apart, thus preventing optimum use of laser diagnostics. The high pressure fluid injector test apparatus includes an upper hub, an upper weldment or housing, a first clamp and stud/nut assembly for securing the upper hub to the upper weldment, a standoff assembly within the upper weldment, a pair of window housings having view glasses within the upper weldment, an injector block assembly and purge plate within the upper weldment for holding an injector element to be tested and evaluated, a lower weldment or housing, a second clamp and stud/nut assembly for securing the lower weldment to the upper weldment, a lower hub, a third clamp and stud/nut assembly for securing the lower hub to the lower weldment, mechanisms for introducing fluid under high pressure for testing an injector element, and mechanisms for purging the apparatus to prevent frosting of view glasses within the window housings and to permit unobstructed viewing of the injector element.

Myers, William Neill↗

NASA NTRS1995

Apparatus for testing high pressure injector elements

An apparatus for testing and evaluating the spray pattern of high pressure fuel injector elements for use in supplying fuel to combustion engines is presented. Prior art fuel injector elements were normally tested by use of low pressure apparatuses which did not provide a purge to prevent mist from obscuring the injector element or to prevent frosting of the view windows; could utilize only one fluid during each test; and had their viewing ports positioned one hundred eighty (180 deg) apart, thus preventing optimum use of laser diagnostics. The high pressure fluid injector test apparatus includes an upper hub, an upper weldment or housing, a first clamp and stud/nut assembly for securing the upper hub to the upper weldment, a standoff assembly within the upper weldment, a pair of window housings having view glasses within the upper weldment, an injector block assembly and purge plate within the upper weldment for holding an injector element to be tested and evaluated, a lower weldment or housing, a second clamp and stud/nut assembly for securing the lower weldment to the upper hub, a third clamp and stud/nut assembly for securing the lower hub to the lower weldment, mechanisms for introducing fluid under high pressure for testing an injector element, and mechanisms for purging the apparatus to prevent frosting of view glasses within the window housings and to permit unobstructed viewing of the injector element.

Myers, William Neill↗

NASA NTRS2005

Using CFD as a Rocket Injector Design Tool: Recent Progress at Marshall Space Flight Center

New programs are forcing American propulsion system designers into unfamiliar territory. For instance, industry s answer to the cost and reliability goals set out by the Next Generation Launch Technology Program are engine concepts based on the Oxygen- Rich Staged Combustion Cycle. Historical injector design tools are not well suited for this new task. The empirical correlations do not apply directly to the injector concepts associated with the ORSC cycle. These legacy tools focus primarily on performance with environment evaluation a secondary objective. Additionally, the environmental capability of these tools is usually one-dimensional while the actual environments are at least two- and often three-dimensional. CFD has the potential to calculate performance and multi-dimensional environments but its use in the injector design process has been retarded by long solution turnaround times and insufficient demonstrated accuracy. This paper has documented the parallel paths of program support and technology development currently employed at Marshall Space Flight Center in an effort to move CFD to the forefront of injector design. MSFC has established a long-term goal for use of CFD for combustion devices design. The work on injector design is the heart of that vision and the Combustion Devices CFD Simulation Capability Roadmap that focuses the vision. The SRL concept, combining solution fidelity, robustness and accuracy, has been established as a quantitative gauge of current and desired capability. Three examples of current injector analysis for program support have been presented and discussed. These examples are used to establish the current capability at MSFC for these problems. Shortcomings identified from this experience are being used as inputs to the Roadmap process. The SRL evaluation identified lack of demonstrated solution accuracy as a major issue. Accordingly, the MSFC view of code validation and current MSFC-funded validation efforts were discussed in some detail. The objectives of each effort were noted. Issues relative to code validation for injector design were discussed in some detail. The requirement for CFD support during the design of the experiment was noted and discussed in terms of instrumentation placement and experimental rig uncertainty. In conclusion, MSFC has made significant progress in the last two years in advancing CFD toward the goal of application to injector design. A parallel effort focused on program support and technology development via the SCIT Task have enabled the progress.

Tucker, Kevin↗

NASA NTRS2010

Transverse Injection into Subsonic Crossflow with Various Injector Orifice Geometries

Computational and experimental results are presented for a case study of single injectors employed in 90 deg transverse injection into a non-reacting subsonic flow. Different injector orifice shapes are used (including circular, square, diamond-shaped, and wide rectangular slot), all with constant cross-sectional area, to observe the effects of this variation on injector penetration and mixing. Whereas the circle, square, and diamond injector produce similar jet plumes, the wide rectangular slot produces a plume with less vertical penetration than the others. There is also some evidence that the diamond injector produces slightly faster penetration with less mixing of the injected fluid. In addition, a variety of rectangular injectors were analyzed, with varying length/width ratios. Both experimental and computational data show improved plume penetration with increased streamwise orifice length. 3-D Reynolds-Averaged Navier-Stokes (RANS) results are obtained for the various injector geometries using NCC (National Combustion Code) with the kappa-epsilon turbulence model in multi-species modes on an unstructured grid. Grid sensitivity results are also presented which indicate consistent qualitative trends in the injector performance comparisons with increasing grid refinement.

Foster, Lancert E.↗

NASA NTRS2014

Designing Liquid Rocket Engine Injectors for Performance, Stability, and Cost

NASA is developing the Space Launch System (SLS) for crewed exploration missions beyond low Earth orbit. Marshall Space Flight Center (MSFC) is designing rocket engines for the SLS Advanced Booster (AB) concepts being developed to replace the Shuttle-derived solid rocket boosters. One AB concept uses large, Rocket-Propellant (RP)-fueled engines that pose significant design challenges. The injectors for these engines require high performance and stable operation while still meeting aggressive cost reduction goals for access to space. Historically, combustion stability problems have been a critical issue for such injector designs. Traditional, empirical injector design tools and methodologies, however, lack the ability to reliably predict complex injector dynamics that often lead to combustion stability. Reliance on these tools alone would likely result in an unaffordable test-fail-fix cycle for injector development. Recently at MSFC, a massively parallel computational fluid dynamics (CFD) program was successfully applied in the SLS AB injector design process. High-fidelity reacting flow simulations were conducted for both single-element and seven-element representations of the full-scale injector. Data from the CFD simulations was then used to significantly augment and improve the empirical design tools, resulting in a high-performance, stable injector design.

Westra, Douglas G.↗

NASA NTRS2016

Design and Fabrication of Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged Combustion Thrust Chamber Injectors

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. On the current project, several configurations of new main injectors were considered for the thrust chamber assembly of the integrated test article. All the injector elements were of the gas-centered swirl coaxial type, similar to those used on the Russian oxidizer-rich staged-combustion rocket engines. In such elements, oxidizer-rich combustion products from the preburner/turbine exhaust flow through a straight tube, and fuel exiting from the combustion chamber and nozzle regenerative cooling circuits is injected near the exit of the oxidizer tube through tangentially oriented orifices that impart a swirl motion such that the fuel flows along the wall of the oxidizer tube in a thin film. In some elements there is an orifice at the inlet to the oxidizer tube, and in some elements there is a sleeve or "shield" inside the oxidizer tube where the fuel enters. In the current project, several variations of element geometries were created, including element size (i.e., number of elements or pattern density), the distance from the exit of the sleeve to the injector face, the width of the gap between the oxidizer tube inner wall and the outer wall of the sleeve, and excluding the sleeve entirely. This paper discusses the design rationale for each of these element variations, including hydraulic, structural, thermal, combustion performance, and combustion stability considerations. This paper also discusses the fabrication and assembly of the injector components, including the injector body/interpropellant plate, the additive manufactured GRCop-84 faceplate, and the pieces that make up the injector elements including the oxidizer tube, an inlet to the oxidizer tube, and a facenut that includes the fuel tangential inlets and forms the initial recessed volume where oxidizer and fuel first interact. Hot-fire test results of these main injector designs in an integrated test article that includes an oxidizer-rich preburner are described in companion papers at this JANNAF meeting.

Garcia, C. P.↗

NASA NTRS2018

Performance, Stability and Compatibility of Oxygen/RP-1 Multi-Element Oxidizer-Rich Staged-Combustion Injectors

In 2015 and 2016, the National Aeronautics and Space Administration Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/RP-1 propellant multi-element oxidizer-rich staged-combustion test article. The main objective was to provide thrust chamber combustion stability data as part of the Combustion Stability Tool Development program, although demonstration of performance and compatibility of oxidizer-rich main injectors was also important. Funding was provided by the Air Force Space and Missile Systems Center. Five configurations of main injectors were designed and fabricated, using conventional gas-centered swirl coaxial injector element designs generally similar to those used in oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines. Variations of element features included element size, recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. Ablative combustion chambers were fabricated based on hardware previously used at the NASA MSFC for testing at similar size and pressure. Existing oxygen/RP-1 oxidizer-rich subscale preburner injectors and hot gas ducts from a previous NASA-funded program were modified for use to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Testing of the resulting integrated test article - which included the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was conducted at Test Stand 116 at the East Test Area of the NASA MSFC. The test article was well instrumented with static and dynamic pressure, temperature, and vibration sensors. This paper presents and discusses all the hot-fire test results of the integrated test article thrust chamber. Eighteen successful hot-fire tests of the integrated rig were conducted. Testing was accomplished with all five of the injector element concepts. Main combustion chamber pressures ranged from 710 to 2350 psia, and main combustion chamber mixture ratios ranged from 2.47 to 2.87. A chamber barrier fuel film coolant of about 2% to 4% of the total fuel flow was used for most tests. Characteristic exhaust velocity efficiency excluding the influence of the fuel film cooling ranged from 91% to 98% of theoretical. All tests of the thrust chamber exhibited stable combustion, even down to 40% of nominal operating pressures. Compatibility of the injector face and combustion chamber walls was acceptable. This paper is a follow-on to publication of preliminary test data presented at the 2016 JANNAF Liquid Propulsion Subcommittee meeting.

Hulka, J. R.↗

NASA NTRS2018

Comparison of Mixing Characteristics for Several Fuel Injectors at Mach 8, 12, and 15 Hypervelocity Flow Conditions

CFD analysis is presented of the mixing characteristics and performance of three fuel injectors at flight Mach numbers of 8, 12, and 15. The Reynolds-averaged simulations (RAS) were carried out using the VULCAN-CFD solver. The high Mach number flow conditions match those of the experiments conducted as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center. The EIMP aims to investigate scramjet fuel injection and mixing physics, improve the understanding of underlying physical processes, and develop enhancement strategies relevant to flight Mach numbers greater than 8. The injectors include a fuel placement device, a strut, and a fluidic vortical mixer, a ramp. These fuel injectors accomplish the necessary task of distributing and mixing fuel into the supersonic cross-flow, albeit via different strategies. For comparison, a flush-wall injector is also included. This type of injector generally represents the simplest method of introducing fuel into a scramjet combustor. The three injectors represent the baseline configurations of the EIMP experiments. The mixing parameters of interest, such as mixing efficiency and total pressure recovery, are computed from the RAS and compared for the three flight conditions and injector configurations. In addition to mixing efficiency and total pressure recovery, the combustion efficiency and thrust potential are also computed for the reacting simulations. Plotting the total pressure recovery and thrust potential as a function of mixing efficiency provides added insight into critical aspects of combustor performance as the flight condition and injector type are varied.

Shenoy, Rajiv R.↗

NASA NTRSDate not supplied

Development of an Additive Manufactured Cryogenic TVS Augmented Injector

Cryogenic fluid transfer is critical in ground and space systems. Transfer typically requires venting a receiver vessel during the chill and fill process to maintain a pressure favorable to fluid flow. Venting in space is problematic due to low-gravity where fluid position is indeterminate; possibly allowing fluid to flow out the vent. To control receiver tank venting the vented chill/no-vent fill methodology is attractive. An additively manufactured Injector coupled with a Thermodynamic Venting System (TVS) augmentation can enable the vented chill/no-vent fill approach with simplified operations. The TVS augmented injector includes an internal heat exchanger, fluid injector spray head, and external surface condensation heat exchange; combined with integrated flow paths in one part. Operations using the injector allow the tank vent to be closed very early in the transfer and not reopened. The TVS circuit eliminates the potential for stalled fill by maintaining cooling flow on the injector and condenser elements, reducing tank pressure. The injector can also be employed for long-term cryo fluid storage as a means of controlling tank pressure if integrated with a recirculation pump. A cryo-cooler can be used in place of/or augmenting the TVS flow circuit for a zero loss pressure control system. The Injector was developed using the principles of design for additive manufacture and printed as one part, resulting in part count reduction, improved reproducibility, shorter lead times, and reduced cost. The TVS augmented injector is compact and highly adaptable simplifying its integration. A key benefit is that this methodology enables simplified operations in reaching 100% fill conditions.

Omar Mireles↗

NASA NTRSDate not supplied

A Review Towards the Design Optimization of High Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist with RDREs over CP engines such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), super-alloy materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major program goal is to rapidly produce ultra-high-performance AM injectors. This paper reviews the available literature on liquid rocket injector design optimization as well as the experimental work conducted to date on injectors tested in RDREs. Major lessons learned are document and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is discussed. Finally, several candidate AM RDRE injector elements were produced to obtain their diodicity and cold flow characteristics.

rotating detonation engine↗

NASA NTRS2016

CFD Based Design of a Filming Injector for N+3 Combustors

An effort was undertaken to perform CFD analysis of fluid flow in Lean-Direct Injection (LDI) combustors with axial swirl-venturi elements for next-generation LDI-3 combustor design. The National Combustion Code (NCC) was used to perform non-reacting and two-phase reacting flow computations for a newly-designed pre-filming type fuel injector LDI-3 injector, in a single-injector and a five-injector array configuration. All computations were performed with a consistent approach of mesh-optimization, spray-modeling, ignition and kinetics-modeling. Computational predictions of the aerodynamics of the single-injector were used to arrive at an optimized main-injector design that meets effective area and fuel-air mixing criteria. Emissions (EINOx) characteristics were predicted for a medium-power engine cycle condition, and will be compared with data when it is made available from experimental measurements. The use of a PDF-like turbulence-chemistry interaction model with NCC's Time-Filtered Navier-Stokes (TFNS) solver is shown to produce a significant impact on the CFD results, when compared with a laminar-chemistry TFNS approach for the five-injector computations.

combustion chambers↗

DOE OSTI2025

Design considerations for optimizing the transient CHI injector on QUEST

Transient coaxial helicity injection (transient CHI) on the QUEST (Q-shu University Experiment with Steady-State ST) spherical tokamak (ST) has recently validated the floating biased electrode configuration for solenoid-free plasma startup. In support of a significant divertor upgrade on QUEST, the details of the transient CHI injector geometry on QUEST have been examined more closely using tokamak simulation code (TSC) simulations. QUEST uses a HIT-II-like (Helicity Injected Torus) injector configuration in which the injector region is comprised of coaxial injector electrodes located in the lower part of the machine. TSC simulations indicate high injector flux operation may benefit from an increased gap between the coaxial electrodes. This is the first study to examine the differences between an open and closed electrode configuration for solenoid-free plasma startup using transient CHI. Results show that both configurations can generate similar levels of closed flux, but the closed configuration may be easier to implement in some ST designs as a much smaller portion of the injector needs to be close to the injector flux coil. Results show that increasing the electrode gap width from the present 10.8 cm to about 15–20 cm would increase the closed flux fraction by about 40%. The results presented in this paper are generally applicable to the CHI design for other STs.

coaxial helicity injection↗

NASA NTRS1981

Effects of fuel-injector design on ultra-lean combustion performance

Emissions data were obtained for six fuel injector configurations tested with ultra lean combustion. Fuel injectors included three multiple source designs and three configurations using a single air assist injector. Only the multiple source fuel injectors provided acceptable emissions. Values of 16g CO/kg fuel, 1.9g HC/kg fuel, and 19.g NO2/kg fuel were obtained for the combustion temperature range of 1450 to 1700 K for both a high blockage 19 source injector and a low blockage 41 source injector. It was shown that high fuel injector pressure drop may not be required to achieve low emissions performance at high inlet air temperature when the fuel is well dispersed in the airstream.

Anderson, D. N.↗

NASA NTRS1990

Airflow Model Testing to Determine the Distribution of Hot Gas Flow and O/F Ratio Across the Space Shuttle Main Engine Main Injector Assembly

Engine 0209, the certification engine for the new Phase 2+ Hot Gas Manifold (HGM), showed severe deterioration of the Main Combustion Chamber (MCC) liner during hot fire tests. One theory on the cause of the damage held that uneven local distribution of the fuel rich hot gas flow through the main injector assembly was producing regions of high oxidizer/fuel (O/F) ratio near the wall of the MCC liner. Airflow testing was proposed to measure the local hot gas flow rates through individual injector elements. The airflow tests were conducted using full scale, geometrically correct models of both the current Phase 2 and the new Phase 2+ HGMs. Different main injector flow shield configurations were tested for each HGM to ascertain their effect on the pressure levels and distribution of hot gas flow. Instrumentation located on the primary faceplate of the main injector measured hot gas flow through selected injector elements. These data were combined with information from the current space shuttle main engine (SSME) power balances to produce maps of pressure, hot gas flow rate, and O/F ratio near the main injector primary plate. The O/F distributions were compared for the different injector and HGM configurations.

Mahorter, L.↗

NASA NTRS1991

Coaxial injector spray characterization using water/air as simulants

Quantitative information about the atomization of injector sprays is required to improve the accuracy of computational models that predict the performance and stability of liquid propellant rocket engines. An experimental program is being conducted at NASA-Lewis to measure the drop size and velocity distributions in shear coaxial injector sprays. A phase/Doppler interferometer is used to obtain drop size data in water air shear coaxial injector sprays. Droplet sizes and axial component of droplet velocities are measured at different radii for various combinations of water flow rate, air flow rate, injector liquid jet diameter, injector annular gap, and liquid post recess. Sauter mean diameters measured in the spray center 51 mm downstream of the liquid post tip range from 28 to 68 microns, and mean axial drop velocities at the same location range from 37 to 120 m/s. The shear coaxial injector sprays show a high degree of symmetry; the mean drop size and velocity profiles vary with liquid flow rate, post recess, and distance from the injector face. The drop size data can be used to estimate liquid oxygen/hydrogen spray drop sizes by correcting property differences between water-air and liquid oxygen/hydrogen.

Zaller, Michelle M.↗

NASA NTRS1993

Inherent stability of central element coaxial liquid-liquid injectors

Most TRW liquid bi-propellant rocket engines built over the past thirty-plus years have employed a central element coaxial pintle injector and have operated with liquid/liquid propellant injection. This injector is a patented design exclusive to TRW and has unique features that make the rocket engine combustion characteristics different from those of other types of injector engine designs. Its many benefits include excellent combustion performance, efficient deep throttling, adaptability to low cost manufacturing, and high reliability. Approximately 200 pintle injector engines of various sizes and operating on a variety of propellants have been flown without a single inflight failure. An especially important feature of the pintle injector engine is its apparent inherent combustion stability. In over thirty years of development, testing, and production, TRW has never experienced combustion instability in any of its pintle injector engine designs. This has been true of engines operating over a range of thrust from 5 to 250,000 lbs. on earth-storable hypergolic propellants and a large number of smaller engines operating on a variety of propellants (21 combinations) in long duration-firing, pulsing (down to 2 msec), and deep throttling (as much as 19:1) modes. Operating chamber pressures have ranged from 10 to 3,500 psia. This record is particularly impressive given that typical TRW design practice does not consider combustion instability as an issue and no pintle engine has ever employed stability-enhancing features, such as baffles or acoustically resonant chambers. In spite of this, TRW engines have operated stably in regimes not possible with other types of injectors. Various physical explanations and combustion process models for this favorable stability characteristic have been postulated. However, a definitive study that unequivocally establishes the important stabilizing mechanisms still remains to be conducted.

Stoddard, Frank J.↗

NASA NTRS2002

Minimally Intrusive and Nonintrusive Supersonic Injectors for LANTR and RBCC/Scramjet Propulsion Systems

A family of supersonic injectors for use on spaceplanes, rockets and missiles and the like is disclosed and claimed. Each injector maintains a specific constant (uniform) Mach number along its length when used while being minimally intrusive at significantly higher injectant pressure than combuster freestream total pressure. Each injector is substantially non-intrusive when it is not being used. The injectors may be used individually or in a group. Different orientations of the injectors in a group promotes greater penetration and mixing of fuel or oxidizer into a supersonic combustor. The injectors can be made from single piece of Aluminum, investment cast metal, or ceramic or they can be made from starboard and port blocks strapped together to accurately control the throat area. Each injector includes an elongated body having an opening which in cross section is an hour glass (venturi shaped) and the opening diverges in width and depth from the bow section to the stem section of the opening.

Alvin E Buggele↗

NASA NTRS2003

Computation of Transverse Injection Into Supersonic Crossflow With Various Injector Orifice Geometries

Computational results are presented for the performance and flow behavior of various injector geometries employed in transverse injection into a non-reacting Mach 1.2 flow. 3-D Reynolds-Averaged Navier Stokes (RANS) results are obtained for the various injector geometries using the Wind code with the Mentor s Shear Stress Transport turbulence model in both single and multi-species modes. Computed results for the injector mixing, penetration, and induced wall forces are presented. In the case of rectangular injectors, those longer in the direction of the freestream flow are predicted to generate the most mixing and penetration of the injector flow into the primary stream. These injectors are also predicted to provide the largest discharge coefficients and induced wall forces. Minor performance differences are indicated among diamond, circle, and square orifices. Grid sensitivity study results are presented which indicate consistent qualitative trends in the injector performance comparisons with increasing grid fineness.

Foster, Lancert↗