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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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NASA NTRS2002

Dual-Mode Combustion

The Department of Mechanical and Aerospace Engineering at the University of Virginia has conducted an investigation of the mixing and combustion processes in a hydrogen fueled dual-mode scramjet combustor. The experiment essentially consisted of the "direct connect" continuous operation of a Mach 2 rectangular combustor with a single unswept ramp fuel injector. The stagnation enthalpy of the test flow simulated a flight Mach number of 5. Measurements were obtained using conventional wall instrumentation and laser based diagnostics. These diagnostics included, pressure and wall temperature measurements, Fuel Plume Imaging (FPI) and Particle Image Velocimetry (PIV). A schematic of the combustor configuration and a summary of the measurements obtained are presented. The experimental work at UVa was parallel by Computational Fluid Dynamics (CFD) work at NASA Langley. The numerical and experiment results are compared in this document.

Goyne, Christopher P.↗
NASA NTRS2002

Aeroheating Environments for a Mars Smart Lander

A proposed Mars Smart Lander is designed to reach the surface via lifting-body atmospheric entry (alpha = 16 deg) to within 10 km of the target site. CFD (computational fluid dynamics) predictions of the forebody aeroheating environments are given for a direct entry from a 2005 launch. The solutions were obtained using an 8-species gas in thermal and chemical nonequilibrium with a radiative-equilibrium wall temperature boundary condition. Select wind tunnel data are presented from tests at NASA Langley Research Center. Turbulence effects are included to account for both smooth body transition and turbulence due to heatshield penetrations. Natural transition is based on a momentum-thickness Reynolds number value of 200. The effects of heatshield penetrations on turbulence are estimated from wind tunnel tests of various cavity sizes and locations. Both natural transition and heatshield penetrations are predicted to cause turbulence prior to the nominal trajectory peak heating time. Laminar and turbulent CFD predictions along the trajectory are used to estimate heat rates and loads. The predicted peak turbulent heat rate of 63 W/sq cm on the heatshield leeward flank is 70% higher than the laminar peak. The maximum integrated heat load for a fully turbulent heat pulse is 38% higher than the laminar load on the heatshield nose. The predicted aeroheating environments with uncertainty factors will be used to design a thermal protection system.

Edquist, Karl T.↗
NASA NTRS2002

Fluid Flow and Solidification Under Combined Action of Magnetic Fields and Microgravity

Mathematical models, both 2-D and 3-D, are developed to represent g-jitter induced fluid flows and their effects on solidification under combined action of magnetic fields and microgravity. The numerical model development is based on the finite element solution of governing equations describing the transient g-jitter driven fluid flows, heat transfer and solutal transport during crystal growth with and without an applied magnetic field in space vehicles. To validate the model predictions, a ground-based g-jitter simulator is developed using the oscillating wall temperatures where timely oscillating fluid flows are measured using a laser PIV system. The measurements are compared well with numerical results obtained from the numerical models. Results show that a combined action derived from magnetic damping and microgravity can be an effective means to control the melt flow and solutal transport in space single crystal growth systems.

Li, B. Q.↗
NASA NTRS2002

Lightweight, Actively Cooled Ceramic Matrix Composite Thrustcells Successfully Tested in Rocket Combustion Lab

In a joint effort between the NASA Glenn Research Center and the NASA Marshall Space Flight Center, regeneratively cooled ceramic matrix composite (CMC) thrustcells were developed and successfully tested in Glenn's Rocket Combustion Lab. Cooled CMC's offer the potential for substantial weight savings over more traditional metallic parts. Two CMC concepts were investigated. In the first of these concepts, an innovative processing approach utilized by Hyper-Therm, Inc., allowed woven CMC coolant containment tubes to be incorporated into the complex thruster design. In this unique design, the coolant passages had varying cross-sectional shapes but maintained a constant cross-sectional area along the length of the thruster. These thrusters were silicon carbide matrix composites reinforced with silicon carbide fibers. The second concept, which was supplied by Ceramic Composites, Inc., utilized copper cooling coils surrounding a carbon-fiber-reinforced carbon matrix composite. In this design, a protective gradient coating was applied to the inner thruster wall. Ceramic Composites, Inc.'s, method of incorporating the coating into the fiber and matrix eliminated the spallation problem often observed with thermal barrier coatings during hotfire testing. The focus of the testing effort was on screening the CMC material's capabilities as well as evaluating the performance of the thermal barrier or fiber-matrix interfacial coatings. Both concepts were hot-fire tested in gaseous O2/H2 environments. The test matrix included oxygen-to-fuel ratios ranging from 1.5 to 7 with chamber pressures to 400 psi. Steady-state internal wall temperatures in excess of 4300 F were measured in situ for successful 30-sec test runs. Photograph of actively cooled composite thrustcell fabricated by Hyper-Therm is shown. The thrustcell is a silicon-carbide-fiber-reinforced silicon carbide matrix composite with woven cooling channels. The matrix is formed via chemical vapor infiltration. Photograph of hot-fire test of an actively cooled carbon-fiber-reinforced carbon matrix composite thrustcell is also shown. This composite thrustcell, which was fabricated by CCI, Inc., was wound with copper cooling coils to contain the water coolant. The tests were run with oxygen fuel ratios up to seven with chamber pressures of 200 psia.

Jaskowiak, Martha H.↗
NASA NTRS2002

Microscale Heaters Detailed Boiling Behavior in Normal Gravity and Microgravity

Pool boiling in microgravity is an area of both scientific and practical interest. Conducting tests in microgravity, as well as lunar and Martian gravity, makes it possible to assess the effect of the density difference between the vapor and liquid phases on the overall boiling process and to assess the relative magnitude of these effects in comparison to other "forces" and phenomena, such as surface tension forces, liquid momentum forces, and microlayer evaporation. The microscale heater developed under a NASA Glenn Research Center grant serves as a unique tool to probe the fundamental mechanisms associated with pool boiling. An experimental package was designed and built by the University of Maryland and tested on the NASA Johnson Space Center KC-135 experimental aircraft and a NASA WFF Terrier Orion Sounding Rocket under NASA Grants NAG3-2228 and NCC3-783. A square array of 96 microscale heaters was constructed and installed into a special boiling chamber. A fluorinert, FC-72, was used as the test fluid. A variety of tests were conducted at different pressures, heater wall temperatures, bulk fluid temperatures, and gravity levels.

McQuillen, John B.↗
NASA NTRS2004

Benchmark Wall Heat Flux Data for a GO2/GH2 Single Element Injector

Computational Fluid Dynamics (CFD) is becoming an important component of injector design in the rocket industry. Injector designers who use CFD in the design process need to understand the accuracy level of the particular code being used for certain aspects of the design. This paper presents a recent effort to acquire benchmark quality data to be used for CFD code validation. Detailed chamber wall temperature and heat flux data was acquired for a gaseous oxygen, gaseous hydrogen single element shear coaxial injector in a 1.5 inch diameter copper heat sink chamber at Penn State University. The data was taken using both coaxial and water cooled heat flux gauges. Tests were run using hot gases generated from both fuel and oxidizer preburners. Tests were conducted over a chamber pressure range of 300 to 750 psia. Data analysis and uncertainty information will also be presented.

Pal, Sibtosh↗
NASA NTRS2004

CFD Code Validation of Wall HeatFluxes for a GO2/GH2 Single Combustor

Computational Fluid Dynamics (CFD) is becoming an important component of injector design in the rocket industry. Injector designers who use CFD in the design process need to understand the accuracy level of the particular code being used for certain aspects of the design. This paper represents a recent effort to demonstrate the accuracy of two CFD codes to calculate the wall heat flux for a single element injector. The FDNS and Loci- CHEM codes currently in use at NASA Marshall Space Flight Center were evaluated. The test case was a single shear coaxial element with gaseous oxygen and hydrogen in a chamber instrumented with coaxial heat flux gauges on the chamber wall down the axis. The data were taken at Penn State University. Measured wall temperatures were used as boundary conditions for the CFD calculations. Calculations were compared to experimental data at chamber pressures of 300,450 600, and 750 psia. The accuracy level of both codes was assessed.

Lin, Jeff↗
NASA NTRS2006

Shuttle Damage/Repair from the Perspective of Hypersonic Boundary Layer Transition - Experimental Results

An overview is provided of the experimental wind tunnel program conducted at the NASA Langley Research Center Aerothermodynamics Laboratory in support of an agency-wide effort to prepare the Shuttle Orbiter for Return-to-Flight. The effect of an isolated protuberance and an isolated rectangular cavity on hypersonic boundary layer transition onset on the windward surface of the Shuttle Orbiter has been experimentally characterized. These experimental studies were initiated to provide a protuberance and cavity effects database for developing hypersonic transition criteria to support on-orbit disposition of thermal protection system damage or repair. In addition, a synergistic experimental investigation was undertaken to assess the impact of an isolated mass-flow entrainment source (simulating pyrolysis/outgassing from a proposed tile repair material) on boundary layer transition. A brief review of the relevant literature regarding hypersonic boundary layer transition induced from cavities and localized mass addition from ablation is presented. Boundary layer transition results were obtained using 0.0075-scale Orbiter models with simulated tile damage (rectangular cavities) of varying length, width, and depth and simulated tile damage or repair (protuberances) of varying height. Cavity and mass addition effects were assessed at a fixed location (x/L = 0.3) along the model centerline in a region of near zero pressure gradient. Cavity length-to-depth ratio was systematically varied from 2.5 to 17.7 and length-to-width ratio of 1 to 8.5. Cavity depth-to-local boundary layer thickness ranged from 0.5 to 4.8. Protuberances were located at several sites along the centerline and port/starboard attachment lines along the chine and wing leading edge. Protuberance height-to-boundary layer thickness was varied from approximately 0.2 to 1.1. Global heat transfer images and heating distributions of the Orbiter windward surface using phosphor thermography were used to infer the state of the boundary layer (laminar, transitional, or turbulent). Test parametrics include angles-of-attack of 30 deg and 40 deg, sideslip angle of 0 deg, freestream Reynolds numbers from 0.02x106 to 7.3x106 per foot, edge-to-wall temperature ratio from 0.4 to 0.8, and normal shock density ratios of approximately 5.3, 6.0, and 12 in Mach 6 air, Mach 10 air, and Mach 6 CF4, respectively. Testing to simulate the effects of ablation from a proposed tile repair concept indicated that transition was not a concern. The experimental protuberance and cavity databases highlighted in this report were used to formulate boundary layer transition correlations that were an integral part of an analytical process to disposition observed Orbiter TPS damage during STS- 114.

Horvath, Thomas J.↗
NASA NTRS2006

Skin Friction at Very High Reynolds Numbers in the National Transonic Facility

Skin friction coefficients were derived from measurements using standard measurement technologies on an axisymmetric cylinder in the NASA Langley National Transonic Facility (NTF) at Mach numbers from 0.2 to 0.85. The pressure gradient was nominally zero, the wall temperature was nominally adiabatic, and the ratio of boundary layer thickness to model diameter within the measurement region was 0.10 to 0.14, varying with distance along the model. Reynolds numbers based on momentum thicknesses ranged from 37,000 to 605,000. The measurements approximately doubled the range of available data for flat plate skin friction coefficients. Three different techniques were used to measure surface shear. The maximum error of Preston tube measurements was estimated to be 2.5 percent, while that of Clauser derived measurements was estimated to be approximately 5 percent. Direct measurements by skin friction balance proved to be subject to large errors and were not considered reliable.

Watson, Ralph D.↗
NASA NTRS2006

Conjugate Heat Transfer Analyses on the Manifold for Ramjet Fuel Injectors

Three-dimensional conjugate heat transfer analyses on the manifold located upstream of the ramjet fuel injector are performed using CFdesign, a finite-element computational fluid dynamics (CFD) software. The flow field of the hot fuel (JP-7) flowing through the manifold is simulated and the wall temperature of the manifold is computed. The three-dimensional numerical results of the fuel temperature are compared with those obtained using a one-dimensional analysis based on empirical equations, and they showed a good agreement. The numerical results revealed that it takes around 30 to 40 sec to reach the equilibrium where the fuel temperature has dropped about 3 F from the inlet to the exit of the manifold.

Wang, Xiao-Yen J.↗
NASA NTRS2007

Intermittency Models and Spot Measurements

Experimental work at the University of Oxford Osney Lab has demonstrated characteristics of the late-stage transition process by the use of thin-film heat transfer gauges. The development of turbulent spots has been observed in a range of environments, including flat plates, turbine blade cascade tests and wake-passing experiments. These results were taken at Mach/Reynolds numbers and gas-to-wall temperature ratios representative of gas turbines. Analyses of the spot characteristics are consistent with measurements taken in low speed experiments, and support the Schubauer and Klebanoff type of turbulent spots. The addition of simulated wakes from upstream stages has been observed to be primarily superpositional for these tests.

Ashworth, D. A.↗
NASA NTRS1954

Permeability and Strength Measurements on Sintered, Porous, Hollow Turbine Blades Made by the American Electro Metal Corporation under Office of Naval Research Contract N-ONR-295 (01)

An experimental investigation was made to determine the permeability and strength characteristics of a number of sintered, porous, hollow turbine rotor blades and to determine the effectiveness of the blade fabrication method on permeability control. The test blades were fabricated by the American Electro Metal Corporation under a contract with the Office of Naval Research, Department of the Navy, and were submitted to the NACA for testing. Of the 22 test blades submitted, ten were sintered but not coined, five were sintered and coined, and seven were sintered and not coined but contained perforated reinforcements integral with the blade shells. Representative samples of each group of blades were tested. Large variations in permeability in both chordwise and spanwise directions were found. Local deviations as large as 155 to -85 percent from prescribed values were found in chordwise permeability. Only one blade, an uncoined one, had a chordwise permeability variations which reasonably approached that specified. Even for this blade, local deviations exceeded 10 percent. Spanwise permeability, specified to be held constant, varied as much as 50 percent from root to tip for both an uncoined and a coined blade. Previous NACA analyses have shown that in order to maintain proper control of blade wall temperatures, permeability variations must not exceed plus or minus 10 percent. Satisfactory control of permeability in either the chordwise or the spanwise direction was not achieved in the blades tested. Spin tests made at room temperature for six blades revealed the highest material rupture strength to be 8926 pounds per square inch. This value is about one third the strength required for rotor blades in present-day turbojet engines. The lowest value of blade strength was 1436 pounds per square inch.

Richards, Hadley T.↗
NASA NTRS2009

A Study of Ablation-Flowfield Coupling Relevant to the Orion Heatshield

The coupled interaction between an ablating surface and the surrounding aerothermal environment is studied. An equilibrium ablation model is coupled to the LAURA flowfield solver, which allows the char ablation rate (m-dot(sub c)) to be computed as part of the flowfield solution. The wall temperature (T(sub w)) and pyrolysis ablation rate (m-dot(sub g)) may be specified by the user, obtained from the steady-state ablation approximation, or computed from a a material response code. A 32 species thermochemical nonequilibrium flowfield model is applied, which permits the treatment of C, H, O, N, and Si containing species. Coupled ablation cases relevant to the Orion heatshield are studied. These consist of diffusion-limited oxidation cases with Avcoat as the ablation material. The m-dot(sub c) values predicted from the developed coupled ablation analysis were compared with those obtained from a typical uncoupled ablation analysis. The coupled results were found to be as much as 50% greater than the uncoupled values. This is shown to be a result of the cumulative effect of the two fundamental approximations inherent in the uncoupled analysis.

Johnston, Christopher O.↗
NASA NTRS2010

The NASA Langley Isolator Dynamics Research Lab

The Isolator Dynamics Research Lab (IDRL) is under construction at the NASA Langley Research Center in Hampton, Virginia. A unique test apparatus is being fabricated to support both wall and in-stream measurements for investigating the internal flow of a dual-mode scramjet isolator model. The test section is 24 inches long with a 1-inch by 2-inch cross sectional area and is supplied with unheated, dry air through a Mach 2.5 converging-diverging nozzle. The test section is being fabricated with two sets (glass and metallic) of interchangeable sidewalls to support flow visualization and laser-based measurement techniques as well as static pressure, wall temperature, and high frequency pressure measurements. During 2010, a CFD code validation experiment will be conducted in the lab in support of NASA s Fundamental Aerodynamics Program. This paper describes the mechanical design of the Isolator Dynamics Research Lab test apparatus and presents a summary of the measurement techniques planned for investigating the internal flow field of a scramjet isolator model.

Middleton, Troy F.↗
NASA NTRS2010

Validation of Heat Transfer and Film Cooling Capabilities of the 3-D RANS Code TURBO

The capabilities of the 3-D unsteady RANS code TURBO have been extended to include heat transfer and film cooling applications. The results of simulations performed with the modified code are compared to experiment and to theory, where applicable. Wilcox s k-turbulence model has been implemented to close the RANS equations. Two simulations are conducted: (1) flow over a flat plate and (2) flow over an adiabatic flat plate cooled by one hole inclined at 35 to the free stream. For (1) agreement with theory is found to be excellent for heat transfer, represented by local Nusselt number, and quite good for momentum, as represented by the local skin friction coefficient. This report compares the local skin friction coefficients and Nusselt numbers on a flat plate obtained using Wilcox's k-model with the theory of Blasius. The study looks at laminar and turbulent flows over an adiabatic flat plate and over an isothermal flat plate for two different wall temperatures. It is shown that TURBO is able to accurately predict heat transfer on a flat plate. For (2) TURBO shows good qualitative agreement with film cooling experiments performed on a flat plate with one cooling hole. Quantitatively, film effectiveness is under predicted downstream of the hole.

Shyam, Vikram↗
NASA NTRS2010

A Heat Transfer Investigation of Liquid and Two-Phase Methane

A heat transfer investigation was conducted for liquid and two-phase methane. The tests were conducted at the NASA Glenn Research Center Heated Tube Facility (HTF) using resistively heated tube sections to simulate conditions encountered in regeneratively cooled rocket engines. This testing is part of NASA s Propulsion and Cryogenics Advanced Development (PCAD) project. Nontoxic propellants, such as liquid oxygen/liquid methane (LO2/LCH4), offer potential benefits in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications. Regeneratively cooled thrust chambers are one solution for high performance, robust LO2/LCH4 engines, but cooling data on methane is limited. Several test runs were conducted using three different diameter Inconel 600 tubes, with nominal inner diameters of 0.0225-, 0.054-, and 0.075-in. The mass flow rate was varied from 0.005 to 0.07 lbm/sec. As the current focus of the PCAD project is on pressure fed engines for LO2/LCH4, the average test section outlet pressures were targeted to be 200 psia or 500 psia. The heat flux was incrementally increased for each test condition while the test section wall temperatures were monitored. A maximum average heat flux of 6.2 Btu/in.2 sec was achieved and, at times, the temperatures of the test sections reached in excess of 1800 R. The primary objective of the tests was to produce heat transfer correlations for methane in the liquid and two-phase regime. For two-phase flow testing, the critical heat flux values were determined where the fluid transitions from nucleate boiling to film boiling. A secondary goal of the testing was to measure system pressure drops in the two-phase regime.

VanNoord, Jonathan↗
NASA NTRS2010

Thermal Performance Expectations of the Advanced Stirling Convertor Over a Range of Operating Scenarios

Objectives of this work are: (1) Assist the Science Mission Directorate in developing technologies for space missions. (2) Explore the capability of computational modeling to assist in the development of the Advanced Stirling Convertor. (3) Baseline computational simulation with available experimental data of the ASC. (4) Calculate peak external pressure vessel wall temperatures and compare them with anticipated values. (5) Calculated peak magnet temperature inside the ASC over a range of operational scenarios.

Reid, Terry V.↗
NASA NTRS2005

Analysis of Heating Rates on the Conical Surface of Apollo Command Module Flying AS-202 Flight

The aerodynamic and aerothermal heating at the leeward surfaces of the Apollo capsule flying high angle of attack were found difficult to simulate using conventional tools. Due to the large subsonic region in the proximity of the shoulder of the base shield, correlation-based tools were found to be inadequate. CFD tools are too time consuming for conceptual design purposes, and cannot account for the transient effects of material response such as wall temperature and blowing. An accurate and timely simulation is essential to effectively size the thermal protection system (TPS), to enhance its performance, and to ensure the safety of the crew. Northrop Grumman Corporation applied a modified version of the MASCC/ATAC program, an inviscid flowfield code with boundary layer solver to simulate this scenario. The MASCC/ATAC code is believed to be the only non-CFD code that can rigorously perform the simulations on the windward surface. The predictions on the windward side of the conical surface were found to be in good agreement with flight data over a wide range of environments. The results are presented in the paper.

Wong, Jim L.↗