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The performance and operating problems of a small hot-gas generator burning liquid hydrogen with liquid oxygen are presented. Two methods of ignition are discussed. Injector and combustion chamber design details based on rocket design criteria are also given. A carefully fabricated showerhead injector of simple design provided a gas generator that yielded combustion efficiencies of 93 and 96 percent.
Basic combustion research is collected, collated, and interpreted as it applies to flight propulsion. The following fundamental processes are treated in separate chapters: atomization and evaporation of liquid fuels, flow and mixing processes in combustion chambers, ignition and flammability of hydrocarbon fuels, laminar flame propagation, turbulent flames, flame stabilization, diffusion flames, oscillations in combustors, and smoke and coke formation in the combustion of hydrocarbon-air mixtures. Theoretical background, basic experimental data, and practical significance to flight propulsion are presented.
The last place you want to be in traffic is behind the bus or truck that is belching large clouds of soot onto your freshly washed car. Besides looking and smelling bad, soot is a health hazard. Particles range from big enough to see to microscopic and can accumulate in the lungs, potentially leading to debilitating or fatal lung diseases. Soot is wasted energy, and therein lies an interesting paradox: Soot forms in a flame's hottest regions where you would expect complete combustion and no waste. Soot enhances the emissions of other pollutants (carbon monoxide and polyaromatic hydrocarbons, etc.) from flames and radiates unwanted heat to combustion chambers (a candle's yellowish glow is soot radiating heat), among other effects. The mechanisms of soot formation are among the most important unresolved problems of combustion science because soot affects contemporary life in so many ways. Although we have used fire for centuries, many fundamental aspects of combustion remain elusive, in part because of limits imposed by the effects of gravity on Earth. Hot or warm air rises quickly and draws in fresh cold air behind it, thus giving flames the classical teardrop shape. Reactions occur in a very small zone, too fast for scientists to observe, in detail, what is happening inside the flame. The Laminar Soot Processes (LSP-2) experiments aboard STS-107 will use the microgravity environment of space to eliminate buoyancy effects and thus slow the reactions inside a flame so they can be more readily studied. 'Laminar' means a simple, smooth fuel jet burning in air, somewhat like a butane lighter. This classical flame approximates combustion in diesel engines, aircraft jet propulsion engines, and furnaces and other devices. LSP-2 will expand on surprising results developed from its first two flights in 1997. The data suggest the existence of a universal relationship, the soot paradigm, that, if proven, will be used to model and control combustion systems on Earth. STS-107 experiments also will help set the stage for extended combustion experiments aboard the International Space Station.
The Skylab fire detector was evaluated in a zero gravity environment. To conduct the test, small samples of spacecraft materials were ignited in a 5 psi oxygen-rich atmosphere inside a combustion chamber. The chamber free-floated in the cabin of a C-135 aircraft, as the aircraft executed a Keplerian parabola. Up to 10 seconds of zero-gravity combustion were achieved. The Skylab fire-detector tubes viewed the flames from a simulated distance of 3m, and color movies were taken to record the nature of the fire. The experiments established the unique form of zero-gravity fires for a wide range of materials. From the tube-output data, the alarm threshold and detector time constant were verified for the Skylab Fire Detection System.
A program to design, fabricate and test a 50 lb sub f (222 N) thruster was undertaken (Contract NAS 3-24656) to demonstrate the applicability of the reverse flow concept as an item of auxiliary propulsion for the space station. The thruster was to operate at a mixture ratio (O/F) of 4, be capable of operating for 2 million lb sub f- seconds (8.896 million N-seconds) impulse with a chamber pressure of 75 psia (52 N/square cm) and a nozzle area ratio of 40. Superimposed was also the objective of operating with a strainless steel spherical combustion chamber, which limited the wall temperature to 1700 F (1200 K), an objective specific impulse of 400 lb sub f sec/lbm (3923 N-seconds/Kg), and a demonstration of 500,000 lb sub f-seconds (2,224,000 N-seconds) of impulse. The demonstration of these objectives required a number of design iterations which eventually culminated in a very successful 1000 second demonstration, almost immediately followed by a changed program objective imposed to redesign and demonstrate at a mixture ratio (O/F) of 8. This change was made and more then 250,000 lb sub f seconds (1,112,000 N-seconds) of impulse was successfully demonstrated at a mixture ratio of 8. This document contains a description of the effort conducted during the program to design and demonstrate the thrusters involved.
A predictive tool for hypergolic bipropellant spray combustion and flow evolution in small rocket combustion chambers is described. It encompasses a computational technique for the gas-phase governing equations, a discrete particle method for liquid bipropellant sprays, and constitutive models for combustion chemistry, interphase exchanges, and unlike impinging hypergolic spray interactions. Emphasis is placed on the phenomenological modeling of the hypergolic liquid bipropellant gasification processes. Sample computations with the N2H4-N2O4 propellant system are given in order to show some of the capabilities and inadequacies of this tool.
An analytical model is formulated for a three-dimensional nonlinear stability problem in a rocket motor combustion chamber. The chamber is modeled as a right circular cylinder with a short (multi-orifice) nozzle, and an acoustic linear covering an arbitrary portion of the cylindrical periphery. The combustion is concentrated at the injector and the gas flow field is characterized by a mean Mach number. The unsteady combustion processes are formulated using the Crocco time lag model. The resulting equations are solved using a Green's function method combined with numerical evaluation techniques. The influence of acoustic liners on the nonlinear waveforms is predicted. Nonlinear stability limits and regions where triggering is possible are also predicted for both lined and unlined combustors in terms of the combustion parameters.
This report describes the AJ10-221, a high performance Iridium-coated Rhenium (Ir-Re) 110 lbf (490N) welded rocket chamber with 286:1 area ratio nozzle. This engine was designed, built, and hot fired for over 6 hours on this program. It demonstrated an I(s) of 321.8 sec, which is 10 sec higher than conventional 110 lbf silicide coated Cb chambers now in use. The approach used in this portion of the program was to demonstrate the performance improvement that can be made by the elimination of fuel film cooling and the use of a high temperature (4000F) (2200C) iridium-coated rhenium (Ir-Re) rocket chamber. Detailed thermal, performance, mechanical, and dynamic design analyses of the full engine were conducted by Aerojet. Two Ir-Re chambers were built to the Aerojet design by Ultramet, using the chemical vapor deposition (CVD) process. Incorporation of a secondary mixing device or Boundary Layer Trip (BLT) within the combustion chamber (Aerojet Patents 4882904 and 4936091) results in improvement in flow uniformity, and a significant life and performance increase. The 110 lbf engine design was verified in bolt-up hardware tests at sea level and altitude. The effects of injector design on performance were studied. Two duplicate injectors were fabricated matching the preferred design and were demonstrated to be interchangeable in operation. One of these units was fabricated matching the preferred design and was demonstrated to be interchangeable in operation. One of these units was welded into a flight type thruster which was tested for an accumulated duration of 22,590 sec in 93 firings, one of which was a continuous burn of two hours. A design deficiency in the C-103 nozzle near the Re-Cb transition joint was discovered, studied and corrected design has been prepared. Workhardening studies have been conducted to investigate methods for increasing the low yield strength of the Re in the annealed conditions. An advanced 490N high performance engine has been demonstrated which, when proven to be capable of withstanding launch vibration, is ready for flight qualification.
This is the second part of a two-part report that describes the AJ10-221, a high performance iridium-coated rhenium (Ir-Re) 110 lbf (490N) welded rocket chamber with 286:1 area ratio nozzle. This engine was designed, built, and hot fired for over 6 hours on this program. It demonstrated an I(s) of 321.8 sec, which is 10 sec higher than conventional 110 lbf silicide coated Cb chambers now in use. The approach used in this portion of the program was to demonstrate the performance improvement that can be made by the elimination of fuel film cooling and the use of a high temperature (4000 F) (2200 C) iridium-coated rhenium (Ir-Re) rocket chamber. Detailed thermal, performance, mechanical, and dynamic design analyses of the full engine were conducted by Aerojet. Two Ir-Re chambers were built to the Aerojet design by Ultramet, using the chemical vapor deposition (CVD) process. Incorporation of a secondary mixing device or Boundary Layer Trip (BLT) within the combustion chamber (Aerojet Patents 4882904 and 4936091) results in improvement in flow uniformity, and a significant life and performance increase. The 110 lbf engine design was verified in bolt-up hardware tests at sea level and altitude. The effects of injector design on performance were studied. Two duplicate injectors were fabricated matching the preferred design and were demonstrated to be interchangeable in operation. One of these units were welded into a flight type thruster which was tested for an accumulated duration of 22,590 sec in 93 firings, one of which was a continuous burn of two hours. A design deficiency in the C-103 nozzle near the Re-Cb transition joint was discovered, studied and corrected design has been prepared. Workhardening studies have been conducted to investigate methods for increasing the low yield strength of the Re in the annealed conditions. An advanced 490N high performance engine has been demonstrated which, when proven to be capable of withstanding launch vibration, is ready for flight qualification.
An additively manufactured thrust chamber assembly was designed and printed using laser powder bed fusion. The NASA-developed material GRCop-42 was used for its high strength and high temperature characteristics. The combustion chamber and nozzle utilize regenerative coolant channels to achieve long duration hot fire tests. Design for additive manufacturing was used to create geometries not easily attainable with traditional machining. The thrust chamber assembly was post processed to ensure print quality and verify for testing. A feed system – encompassing all propellant lines, valves, sensors, and tanks – was designed and built to enable steady state, pressure regulated testing. Pressure transducers, thermocouples, and load cells were placed to enable measurements of the propellant properties and engine performance. Venturis and orifices were used throughout the system to control the flow rates to the thrust chamber. Aside from providing propellants, the feed system provides pressure using nitrogen, and purges the lines during shutdown. The design process for this testing platform is described. A testing campaign on the hardware will be conducted by the Akronauts Rocket Design Team at the University of Akron in Spring 2023.
An additively manufactured thrust chamber assembly was designed and printed using laser powder bed fusion. The NASA-developed material GRCop-42 was used for its high strength and high temperature characteristics. The combustion chamber and nozzle utilize regenerative coolant channels to achieve long duration hot fire tests. Design for additive manufacturing was used to create geometries not easily attainable with traditional machining. The thrust chamber assembly was post processed to ensure print quality and verify for testing. A feed system – encompassing all propellant lines, valves, sensors, and tanks – was designed and built to enable steady state, pressure regulated testing. Pressure transducers, thermocouples, and load cells were placed to enable measurements of the propellant properties and engine performance. Venturis and orifices were used throughout the system to control the flow rates to the thrust chamber. Aside from providing propellants, the feed system provides pressure using nitrogen, and purges the lines during shutdown. The design process for this testing platform is described. A testing campaign on the hardware will be conducted by the Akronauts Rocket Design Team at the University of Akron in Spring 2023.
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.
The object of the investigation presented in this report was to determine the effects of increasing the air charge and scavenging the clearance volume of a 4-stroke-cycle compression-ignition engine having a vertical-disk form combustion chamber. Boosting the inlet-air pressure with normal valve timing increased the indicated engine power in proportion to the additional air inducted and resulted in smoother engine operation with less combustion shock. Scavenging the clearance volume by using a valve overlap of 145 degrees and an inlet-air boost pressure of approximately 2 1/2 inches of mercury produced a net increase in performance for clear exhaust operation of 33 percent over that obtained with normal valve timing and the same boost pressure. The improved combustion characteristics result in lower specific fuel consumption, and a clearer exhaust.
Two nonintrusive flowfield diagnostics based on spectrally-resolved elastic (Rayleigh) and inelastic (Raman) laser light scattering were developed for obtaining local flowfield measurements in low-thrust gaseous H2/O2 rocket engines. The objective is to provide an improved understanding of phenomena occurring in small chemical rockets in order to facilitate the development and validation of advanced computational fluid dynamics (CFD) models for analyzing engine performance. The laser Raman scattering diagnostic was developed to measure major polyatomic species number densities and rotational temperatures in the high-density flowfield region extending from the injector through the chamber throat. Initial application of the Raman scattering diagnostic provided O2 number density and rotational temperature measurements in the exit plane of a low area-ratio nozzle and in the combustion chamber of a two-dimensional, optically-accessible rocket engine. In the low-density nozzle exit plane region where the Raman signal is too weak, a Doppler-resolved laser Rayleigh scattering diagnostic was developed to obtain axial and radial mean gas velocities, and in certain cases, H2O translational temperature and number density. The results from these measurements were compared with theoretical predictions from the RPLUS CFD code for analyzing rocket engine performance. Initial conclusions indicate that a detailed and rigorous modeling of the injector is required in order to make direct comparisons between laser diagnostic measurements and CFD predictions at the local level.
The analyses, designs, fabrication, and cold-flow acceptance testing of LOX/RP-1 preburner components required for a high-pressure staged-combustion rocket engine are discussed. Separate designs of injectors, combustion chambers, turbine simulators, and hot-gas mixing devices are provided for fuel-rich and oxidizer-rich operation. The fuel-rich design addresses the problem of non-equilibrium LOX/RP-1 combustion. The development and use of a pseudo-kinetic combustion model for predicting operating efficiency, physical properties of the combustion products, and the potential for generating solid carbon is presented. The oxygen-rich design addresses the design criteria for the prevention of metal ignition. This is accomplished by the selection of materials and the generation of well-mixed gases. The combining of unique propellant injector element designs with secondary mixing devices is predicted to be the best approach.
The Lewis Research Center is developing a series of microgravity combustion experiments for the Space Shuttle. The Solid Surface Combustion Experiment (SSCE) is the first to be completed. SSCE will study flame spreading over thermally thin fuels (ashless filter paper) under microgravity conditions. The flight hardware consists of a combustion chamber containing the sample and a computer which takes the data and controls the experiment. Experimental data will include gas-phase and solid-phase temperature measurements and motion pictures of the combustion process. Flame spread rates will be determined from the motion pictures.
The Lewis Research Center is developing a series of microgravity combustion experiments for the Space Shuttle. The Solid Surface Combustion Experiment (SSCE) is the first to be completed. SSCE will study flame spreading over thermally thin fuels (ashless filter paper) under microgravity conditions. The flight hardware consists of a combustion chamber containing the sample and a computer which takes the data and controls the experiment. Experimental data will include gas-phase and solid-phase temperature measurements and motion pictures of the combustion process. Flame spread rates will be determined from the motion pictures.