Nuclear rocket design approach
NERVA nuclear rocket engine design technology program, discussing probabilistic techniques for reliability engineering
Helms, I. L.↗
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An Examination of Materials in Launch Vehicle Propulsion
The primary activities carried out for this effort used Mr. Glasgow's communication skills and materials expertise. He worked closely with both the Space Transportation Project Office and the Materials Division, preparing summaries of the weekly Space Transportation Project Office activities for use by the Materials and the Structures Divisions and for distribution to other portions of the GRC. Mr. Glasgow participated in systems analysis and planning sessions of the Program Office, serving as both a representative of the microtechnologists and as a reviewer of the macrotechnologies involved in proposed new launch vehicles. He helped define the technology readiness level of those new vehicle concepts and provided especially critical expertise to provide realistic technical assessments to various vehicle proponents. While a major portion of his work was performed at the GRC site, travel was required to Langley and to Nashville. In addition to the written contributions mentioned above, he presented summaries of Materials Division activities and interests in industry briefings. Mr. Glasgow continued his interest in the copper-chromium-niobium alloy system, a system originally identified by him as a potential rocket engine material and now chosen as baseline for two new rocket engine designs by the leading US builder of rocket engines.
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LOX/hydrocarbon rocket engine analytical design methodology development and validation. Volume 2: Appendices
This final report includes a discussion of the work accomplished during the period from Dec. 1988 through Nov. 1991. The objective of the program was to assemble existing performance and combustion stability models into a usable design methodology capable of designing and analyzing high-performance and stable LOX/hydrocarbon booster engines. The methodology was then used to design a validation engine. The capabilities and validity of the methodology were demonstrated using this engine in an extensive hot fire test program. The engine used LOX/RP-1 propellants and was tested over a range of mixture ratios, chamber pressures, and acoustic damping device configurations. This volume contains time domain and frequency domain stability plots which indicate the pressure perturbation amplitudes and frequencies from approximately 30 tests of a 50K thrust rocket engine using LOX/RP-1 propellants over a range of chamber pressures from 240 to 1750 psia with mixture ratios of from 1.2 to 7.5. The data is from test configurations which used both bitune and monotune acoustic cavities and from tests with no acoustic cavities. The engine had a length of 14 inches and a contraction ratio of 2.0 using a 7.68 inch diameter injector. The data was taken from both stable and unstable tests. All combustion instabilities were spontaneous in the first tangential mode. Although stability bombs were used and generated overpressures of approximately 20 percent, no tests were driven unstable by the bombs. The stability instrumentation included six high-frequency Kistler transducers in the combustion chamber, a high-frequency Kistler transducer in each propellant manifold, and tri-axial accelerometers. Performance data is presented, both characteristic velocity efficiencies and energy release efficiencies, for those tests of sufficient duration to record steady state values.
Niiya, Karen E.↗
SPACE-CHARGE-FLOW THEORY AND ELECTRODE DESIGN FOR ELECTROSTATIC ROCKET ENGINES
Space charge-flow theory and electrode design for electrostatic rocket engines
ELECTRODE↗
Designing Liquid Rocket Engine Injectors for Performance, Stability, and Cost
No abstract available
West, Jeffrey↗
Designing Liquid Rocket Engine Injectors for Performance, Stability, and Cost
No abstract available
Westra, Douglas G.↗
Enhancement and Extension of Porosity Model in the FDNS-500 Code to Provide Enhanced Simulations of Rocket Engine Components
In the past, the design of rocket engines has primarily relied on the cold flow/hot fire test, and the empirical correlations developed based on the database from previous designs. However, it is very costly to fabricate and test various hardware designs during the design cycle, whereas the empirical model becomes unreliable in designing the advanced rocket engine where its operating conditions exceed the range of the database. The main goal of the 2nd Generation Reusable Launching Vehicle (GEN-II RLV) is to reduce the cost per payload and to extend the life of the hardware, which poses a great challenge to the rocket engine design. Hence, understanding the flow characteristics in each engine components is thus critical to the engine design. In the last few decades, the methodology of computational fluid dynamics (CFD) has been advanced to be a mature tool of analyzing various engine components. Therefore, it is important for the CFD design tool to be able to properly simulate the hot flow environment near the liquid injector, and thus to accurately predict the heat load to the injector faceplate. However, to date it is still not feasible to conduct CFD simulations of the detailed flowfield with very complicated geometries such as fluid flow and heat transfer in an injector assembly and through a porous plate, which requires gigantic computer memories and power to resolve the detailed geometry. The rigimesh (a sintered metal material), utilized to reduce the heat load to the faceplate, is one of the design concepts for the injector faceplate of the GEN-II RLV. In addition, the injector assembly is designed to distribute propellants into the combustion chamber of the liquid rocket engine. A porosity mode thus becomes a necessity for the CFD code in order to efficiently simulate the flow and heat transfer in these porous media, and maintain good accuracy in describing the flow fields. Currently, the FDNS (Finite Difference Navier-Stakes) code is one of the CFD codes which are most widely used by research engineers at NASA Marshall Space Flight Center (MSFC) to simulate various flow problems related to rocket engines. The objective of this research work during the 10-week summer faculty fellowship program was to 1) debug the framework of the porosity model in the current FDNS code, and 2) validate the porosity model by simulating flows through various porous media such as tube banks and porous plate.
Cheng, Gary↗
Advanced Development Program for a 625 lbf thrust engine for Ares First Stage Roll Control System
NASA's new Ares Launch Vehicle will require twelve thrusters to provide roll control of the vehicle during the first stage firing. All twelve roll control thrusters will be located at the inter-stage segment that separates the solid rocket booster first stage from the second stage. NASA selected a mono propellant hydrazine solution and as a result awarded Aerojet-General a contract in 2007 for an advanced development program for an MR-80- series 625 Ibf vacuum thrust monopropellant hydrazine thruster. This thruster has heritage dating back to the 1976 Viking Landers and most recently for the 2011 Mars Science Laboratory. Prior to the Ares application, the MR-80-series thrusters had been equipped with throttle valves and not typically operated in pulse mode. The primary objective of the advanced development program was to increase the technology readiness level and retire major technical risks for the future flight qualification test program. Aerojet built on their heritage MR-80 rocket engine designs to achieve the design and performance requirements. Significant improvements to cost and lead-time were achieved by applying Design for Manufacturing and Assembly (DFMA) principles. AerojetGeneral has completed Preliminary and Critical Design Reviews, followed by two successful rocket engine development test programs. The test programs included qualification random vibration and firing lite that significantly exceed the flight qualification requirements. This paper discusses the advanced development program and the demonstrated capability of the MR-80C engine. Y;
Dawson, Matt↗
A Design Tool for Liquid Rocket Engine Injectors
A practical design tool which emphasizes the analysis of flowfields near the injector face of liquid rocket engines has been developed and used to simulate preliminary configurations of NASA's Fastrac and vortex engines. This computational design tool is sufficiently detailed to predict the interactive effects of injector element impingement angles and points and the momenta of the individual orifice flows and the combusting flow which results. In order to simulate a significant number of individual orifices, a homogeneous computational fluid dynamics model was developed. To describe sub- and supercritical liquid and vapor flows, the model utilized thermal and caloric equations of state which were valid over a wide range of pressures and temperatures. The model was constructed such that the local quality of the flow was determined directly. Since both the Fastrac and vortex engines utilize RP-1/LOX propellants, a simplified hydrocarbon combustion model was devised in order to accomplish three-dimensional, multiphase flow simulations. Such a model does not identify drops or their distribution, but it does allow the recirculating flow along the injector face and into the acoustic cavity and the film coolant flow to be accurately predicted.
Farmer, R.↗
The performance characteristics and mission capabilities of the nuclear rocket engine.
Nuclear rocket engine design for near-optimum vehicle performance for mission capability
MISSION PLANNING↗
A shock wave capability for the improved Two-Dimensional Kinetics (TDK) computer program
The Two Dimensional Kinetics (TDK) computer program is a primary tool in applying the JANNAF liquid rocket engine performance prediction procedures. The purpose of this contract has been to improve the TDK computer program so that it can be applied to rocket engine designs of advanced type. In particular, future orbit transfer vehicles (OTV) will require rocket engines that operate at high expansion ratio, i.e., in excess of 200:1. Because only a limited length is available in the space shuttle bay, it is possible that OTV nozzles will be designed with both relatively short length and high expansion ratio. In this case, a shock wave may be present in the flow. The TDK computer program was modified to include the simulation of shock waves in the supersonic nozzle flow field. The shocks induced by the wall contour can produce strong perturbations of the flow, affecting downstream conditions which need to be considered for thrust chamber performance calculations.
Nickerson, G. R.↗
Probabilistic design applications for the Space Transportation Main Engines
All of the current rocket engine designs are based on deterministic design analysis methods. The most recently designed engine, Space Shuttle Main Engines (SSME), was designed and developed using these techniques in the 1970's and 80's. The Space Transportation Main Engine (STME) design objective is to use a robust design methodology and to pro-actively assess and improve the design during the design process. The design approach is a combination of the traditional deterministic methodologies and recently developed probabilistic methodologies. The designer must use a more rigorous structural criteria, conduct pro-active reliability assessments (reliability allocations, failure modes and effects analysis, reliability growth studies, and design reliability assessment), use a damage tolerant design philosophy and perform probabilistic analyses. Rigorous application of this structured methodology will develop a better engine product.
Ohara, Kevin↗
On the design of acoustic liners for rocket engines - Maximum damping as a design objective
Parameters of acoustic liner for maximum liner damping for rocket engines
Phillips, B.↗
A hydrogen-oxygen rocket engine coolant passage design program (RECOP) for fluid-cooled thrust chambers and nozzles
The design of coolant passages in regeneratively cooled thrust chambers is critical to the operation and safety of a rocket engine system. Designing a coolant passage is a complex thermal and hydraulic problem requiring an accurate understanding of the heat transfer between the combustion gas and the coolant. Every major rocket engine company has invested in the development of thrust chamber computer design and analysis tools; two examples are Rocketdyne's REGEN code and Aerojet's ELES program. In an effort to augment current design capabilities for government and industry, the NASA Lewis Research Center is developing a computer model to design coolant passages for advanced regeneratively cooled thrust chambers. The RECOP code incorporates state-of-the-art correlations, numerical techniques and design methods, certainly minimum requirements for generating optimum designs of future space chemical engines. A preliminary version of the RECOP model was recently completed and code validation work is in progress. This paper introduces major features of RECOP and compares the analysis to design points for the first test case engine; the Pratt & Whitney RL10A-3-3A thrust chamber.
Tomsik, Thomas M.↗
Development and Test of a Rocket Engine Using Environmentally Friendly Propellants
Develop and test a rocket engine that operates on environmentally friendly propellants; Liquid Oxygen (LOX) and Liquid Methane (LCH4). Due to modifications the rocket engine designed last summer (KJ_REX) is not the same rocket thruster tested this summer, but very similar. The new modified rocket thruster was built for NASA by Orion Propulsion Inc. (OPI), Huntsville, AL.
Webster, Kristi↗
On the use of a three-dimensional Navier-Stokes solver for rocket engine pump impeller design
A 3D Reynolds-averaged Navier-Stokes Solver and a Fast Grid Generator (FGG), developed specially for centrifugal impeller design, were incorporated into the pump impeller design process. The impeller performance from the CFD analysis was compared to one-dimensional prediction. Both analyses showed good agreement of the impeller hydraulic efficiency, 94.5 percent, but with an 8 percent discrepancy of Euler head prediction. The impeller blade angle, discharge hub to shroud width, axial length and blade stacking were systematically changed to achieve an optimum impeller design. Impeller overall efficiency, loss distribution, hub-to-tip flow angle distortion and blade-to-blade flow angle change are among those criteria used to evaluate impeller performance. Two grid sizes, one with 10 K grid points and one with 80 K grid points were used to evaluate grid dependency issues. The effects of grid resolution on the accuracy and turnaround time are discussed. In conclusion, it is demonstrated that CFD can be effectively used for design and optimization of rocket engine pump components.
Chen, Wei-Chung↗
Fabrication and Testing of Ceramic Matrix Composite Rocket Propulsion Components
The National Aeronautics and Space Administration (NASA) is pursuing using ceramic matrix composites (CMC) as primary structural components for advanced rocket engines. This endeavor is due to the requirement of increasing safety by two orders of magnitude and reducing costs from $10,000/lb to $1,000/lb both within ten years. Out year goals are even more aggressive. Safety gains, through using CMCS, will be realized by increasing temperature margins, tolerance for extreme thermal transients, and damping capability of components and systems, by using components with lower weight and thermal conductivity, etc. Gains in cost reduction, through using CMCS, are anticipated by enabling higher performance systems, using lighter weight components and systems, enabling 100 mission reusability without system refurbishment, greatly reducing cooling requirements and erosion rates, selecting safe fabrication processes that are ideally cost competitive with metal processes at low volume production, etc. This philosophy contrasts the previous philosophy of rocket engine development focused largely on achieving the highest performance with metals and ablatives -- cost and safety were not the focal point of the initial design. Rocket engine components currently being pursued, largely C/SiC and SiC/SiC, include blisks or rotors, 10 foot by 8 foot nozzle ramps, gas generators, thrust chambers, and upperstage nozzles. The Simplex Turbopump CMC blisk effort has just successfully completed a 4.5 year development and test program. The other components mentioned are in the design or fabrication stage. Although the temperature limits of the CMC materials are not quantified in a realistic environment yet, CMC materials are projected to be the only way to achieve significant safety risks mitigation and cost reductions simultaneously. We, the end-users, material fabricators, technology facilitators, and government organizations are charged with developing and demonstrating a much safer and a lot less costly Earth-to-Orbit full-scale propulsion system by 2005.
Effinger, Michael↗
Study of solid rocket motor for space shuttle booster, volume 2, book 1
The technical requirements for the solid propellant rocket engine to be used with the space shuttle orbiter are presented. The subjects discussed are: (1) propulsion system definition, (2) solid rocket engine stage design, (3) solid rocket engine stage recovery, (4) environmental effects, (5) manrating of the solid rocket engine stage, (6) system safety analysis, and (7) ground support equipment.
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