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NASA NTRS1999

Thermographic Leak Detection of the Space Shuttle Main Engine Nozzle

The Space Shuttle Main Engines Nozzles consist of over one thousand tapered Inconel coolant tubes brazed to a stainless steel structural jacket. Liquid Hydrogen flows through the tubing, from the aft to forward end of the nozzle, under high pressure to maintain a thermal balance between the rocket exhaust and the nozzle wall. Three potential problems occur within the SSME nozzle coolant tubes as a result of manufacturing anomalies and the highly volatile service environment including poor or incomplete bonding of the tubes to the structural jacket, cold wall leaks and hot wall leaks. Of these conditions the identification of cold wall leaks has been the most problematic. The methods and results presented in this summary addresses the thermographic identification of cold wall "interstitial" leaks between the structural jacket and coolant tubes of the Space Shuttle Main Engines Nozzles.

Walker, James L.↗

NASA NTRS1998

Technical Challenges for Next Generation Liquid Rocket Engine Nozzles

Next generation launch and propulsion systems face significant challenges of providing increased performance at lower cost with shorter development cycles. The use of existing materials in new application areas and the development and application of "advanced" material systems are enabling for the achievement of these aggressive goals. An area which offers substantial opportunity to decrease liquid rocket engine systems weight, and thus provide a measure of increased performance, is the nozzle. This presentation will examine the technical issues and showstoppers limiting the application of alternate materials to liquid rocket engine nozzles and identify the key material systems which have the potential for high payoff relative to the forcing functions of cost and performance (weight). Existing nozzle material development projects will be cited and opportunities for future joint partnerships to address these materials and processes challenges will be addressed. The presentation will include overviews of activities in low cost ablative nozzles, ceramic matrix composite cooled and uncooled nozzles, and advanced metallics.

Clinton, R. G., Jr.↗

NASA NTRS2000

Inviscid Design of Hypersonic Wind Tunnel Nozzles for a Real Gas

A straightforward procedure has been developed to quickly determine an inviscid design of a hypersonic wind tunnel nozzle when the test crash is both calorically and thermally imperfect. This real gas procedure divides the nozzle into four distinct parts: subsonic, throat to conical, conical, and turning flow regions. The design process is greatly simplified by treating the imperfect gas effects only in the source flow region. This simplification can be justified for a large class of hypersonic wind tunnel nozzle design problems. The final nozzle design is obtained either by doing a classical boundary layer correction or by using this inviscid design as the starting point for a viscous design optimization based on computational fluid dynamics. An example of a real gas nozzle design is used to illustrate the method. The accuracy of the real gas design procedure is shown to compare favorably with an ideal gas design based on computed flow field solutions.

Korte, J. J.↗

NASA NTRS2000

Acoustic and Aerothermal Performance Test of the Axisymmetric Coannular Ejector Nozzle: Acoustic Performance - Volume 2

Acoustic and propulsion performance testing of a model-scale Axisymmetric Coannular Ejector nozzle was conducted in the Boeing Low-speed Aeroacoustic Facility. This nozzle is a plug nozzle with an ejector design to provide aspiration of about 20% of the engine flow. A variety of mixing enhancers were designed to promote mixing of the engine and the aspirated flows. These included delta tabs, tone-injection rods, and wheeler ramps. This report addresses the acoustic aspects of the testing. The spectral characteristics of the various configurations of the nozzle are examined on a model-scale basis. This includes indentifying particular noise sources contributing to the spectra and the data are projected to full-scale flyover conditions to evaluate the effectiveness of the nozzle, and of the various mixing enhancers, on reducing the Effective Perceived Noise Levels.

Herkes, William↗

NASA NTRS1999

Effect of Boattail and Sidewall Curvature on Nozzle Drag Characteristics

The NASA-industry team has sponsored several studies in the last two years to address the installed nozzle boattail drag issues. Some early studies suggested that nozzle boattail drag could be as much as 25 to 40 percent of the subsonic cruise. As part of this study tests have been conducted at NASA-Langley to determine the uninstalled drag characteristics of a proposed nozzle. The overall objective was to determine the effects of nozzle external flap curvature and sidewall boattail variations. This test would also provide data for validating CFD predictions of nozzle boattail drag.

Capone, Francis J.↗

NASA NTRS2000

Study of Mixing Enhancement Observed with a Co-Annular Nozzle Configuration

Jet spreading enhancement with a certain coannular nozzle configuration has been explored. When the outer nozzle is flaired (i.e., made convergent-divergent) the ensuing jet spreads faster than the case where the outer nozzle is convergent. The spreading enhancement is most pronounced when the outer flow is run near 'transonic' condition, in an overexpanded state. Under this condition, the increased spreading takes place regardless of the operating conditions of the inner jet. This observation, first made in a small scale facility, has been confirmed and studied in some detail in a larger-scale facility. Results of the latter experiment are presented in this paper. The spreading increase is shown to be substantial and comparable to or better than that achieved by a lobed nozzle. Estimates based on idealized flow indicate that there is an accompanying thrust penalty - the actual penalty is expected to be less than the estimate but remains undetermined at this time. In both the earlier and the present experiments, the spreading increase has often been found to accompany a flow resonance. The nature of this resonance is addressed in this paper. It is shown that the spreading increase takes place even if the resonance is absent. Thus, flow excitation due to the resonance is ruled out as the underlying mechanism. While the complete mechanism remains unclear, it is conjectured that pressure gradients near the nozzle, characteristic of overexpanded flow, are at the root of the phenomenon.

Zaman, K. B. M. Q.↗

NASA NTRS1999

Effect of Boattail and Sidewall Curvature on Nozzle Drag Characteristics

Capone, Francis J.↗

NASA NTRS2000

MC-1 Nozzle Testing Results

This document is the presentation graphics which reviews the test results of the MC-1 Nozzle. The MC-1 Nozzle was originally designed for a low cost engine for an expendable booster. It was modified for use in the X-34 propulsion plant. With this design the nozzle and chamber are one piece. The presentation reviews the design goals, the materials and fabrication. The tests and results are reviewed in considerable detail. Included are pictures of the nozzle, and diagrams of the nozzle geometry

Peters, Warren↗

NASA NTRS2001

Computational Analysis of a Pylon-Chevron Core Nozzle Interaction

In typical engine installations, the pylon of an engine creates a flow disturbance that interacts with the engine exhaust flow. This interaction of the pylon with the exhaust flow from a dual stream nozzle was studied computationally. The dual stream nozzle simulates an engine with a bypass ratio of five. A total of five configurations were simulated all at the take-off operating point. All computations were performed using the structured PAB3D code which solves the steady, compressible, Reynolds-averaged Navier-Stokes equations. These configurations included a core nozzle with eight chevron noise reduction devices built into the nozzle trailing edge. Baseline cases had no chevron devices and were run with a pylon and without a pylon. Cases with the chevron were also studied with and without the pylon. Another case was run with the chevron rotated relative to the pylon. The fan nozzle did not have chevron devices attached. Solutions showed that the effect of the pylon is to distort the round Jet plume and to destroy the symmetrical lobed pattern created by the core chevrons. Several overall flow field quantities were calculated that might be used in extensions of this work to find flow field parameters that correlate with changes in noise.

Thomas, Russell H.↗

NASA NTRS2001

Computational Analyses of Propulsion Aeroacoustics for Mixed Flow Nozzle Pylon Installation at Takeoff

A CFD analyses is presented for a set of baseline and noise suppression mixed flow nozzles with and without a pylon installation. The five model configurations are as follows; a baselinecore/fan dual-stream nozzle with an external plug, a chevron mixer nozzle with a peak on the symmetry plane with external plug, both of the above nozzles with an installed bifurcatingpylon and lastly a clocked chevron mixer nozzle such that a trough is aligned with the center of the pylon. The fluid flow is simulated by solving the asymptotically steady, compressible, Reynolds-averaged Navier-Stokes equations using an implicit, up-wind, flux-difference splitting finite volume scheme and standard two equation k-epsilon turbulence model with a linear stress representation. All computations are performed using the multiblock, parallel, structuredcode PAB3D. Results indicate that the clocked chevron with pylon case achieves the most optimal levels of average and peak turbulence kinetic energy and vorticity and therefore is expected to be the quietest of the five configurations tested. Further study is required to refine expressions which are indicative of noise and mate these with rigorous noise prediction models.

Massey, Steven J.↗

NASA NTRS1998

Experimental and Computational Boundary-Layer Studies In a Supersonic Two-Dimensional Nozzle

Experiments and computations were carried out on the adiabatic laminar boundary layer developing along the surfaces of a two-dimensional supersonic nozzle, consisting of upper and lower contoured nozzle blocks and flat sidewalls. Two- and three-dimensional Navier-Stokes codes, as well as two-dimensional boundary-layer codes were employed. These codes were adapted to the characteristics of a specific wind tunnel nozzle, so that their numerical results could be directly compared with experimental data obtained in the same nozzle. Such comparisons were made for the boundary-layer growth on the nozzle contoured surfaces, and for the boundary-layer growth, surface streamlines and surface shear on the sidewalls. The three-dimensional Navier-Stokes code was found to be the only one to correctly predict the mean laminar boundary-layer flow on both the sidewalls and the contoured surfaces. Theory and experiment both indicated that the sidewall flow is highly three-dimensional, with non-uniform shear, corner vortices and a boundary layer strongly distorted by cross flows induced by lateral pressure gradients.

Demetriades, Anthony↗

NASA NTRS2002

Progress in the Development of a Nozzle Design Methodology for Pulsed Detonation Engines

The Johns Hopkins University Applied Physics Laboratory (JHU/APL), in support of the NASA Glenn Research Center (NASA GRC), is investigating performance methodologies and system integration issues related to Pulsed Detonation Engine (PDE) nozzles. The primary goal of this ongoing effort is to develop design and performance assessment methodologies applicable to PDE exit nozzle(s). APL is currently focusing its efforts on a common plenum chamber design that collects the exhaust products from multiple PDE tubes prior to expansion in a single converging-diverging exit nozzle. To accomplish this goal, a time-dependent, quasi-one-dimensional analysis for determining the flow properties in and through a single plenum and exhaust nozzle is underway. In support of these design activities, parallel modeling efforts using commercial Computational Fluid Dynamics (CFD) software are on-going. These efforts include both two and three-dimensional as well as steady and time-dependent computations to assess the flow in and through these devices. This paper discusses the progress in developing this nozzle design methodology.

Leary, B. A.↗

NASA NTRS2003

Leak Location and Classification in the Space Shuttle Main Engine Nozzle by Infrared Testing

The Space Shuttle Main Engine (SSME) is composed of cooling tubes brazed to the inside of a conical structural jacket. Because of the geometry there are regions that can't be inspected for leaks using the bubble solution and low-pressure method. The temperature change due escaping gas is detectable on the surface of the nozzle under the correct conditions. The methods and results presented in this summary address the thermographic identification of leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute temperature change associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Russell, Samuel S.↗

NASA NTRS2001

Density Fluctuation in Asymmetric Nozzle Plumes and Correlation with Far Field Noise

A comparative experimental study of air density fluctuations in the unheated plumes of a circular, 4-tabbed-circular, chevron-circular and 10-lobed rectangular nozzles was performed at a fixed Mach number of 0.95 using a recently developed Rayleigh scattering based technique. Subsequently, the flow density fluctuations are cross-correlated with the far field sound pressure fluctuations to determine sources for acoustics emission. The nearly identical noise spectra from the baseline circular and the chevron nozzles are found to be in agreement with the similarity in spreading, turbulence fluctuations, and flow-sound correlations measured in the plumes. The lobed nozzle produced the least low frequency noise, in agreement with the weakest overall density fluctuations and flow-sound correlation. The tabbed nozzle took an intermediate position in the hierarchy of noise generation, intensity of turbulent fluctuation and flow-sound correlation. Some of the features in the 4-tabbed nozzle are found to be explainable in terms of splitting of the jet in a central large core and 4 side jetlets.

Panda, J.↗

NASA NTRS2005

Acoustic and Aero-Mixing Experimental Results for Fluid Shield Scale Model Nozzles

The principle objectives of this investigation are to evaluate the acoustic and aerodynamic characteristics of fluid shield nozzle concept and to assess Far 36, Stage 3 potential for fluid shield nozzle with Flade Cycle. Acoustic data for nine scale model nozzle configurations are obtained. The effects of simulated flight and geometric and aerothermodynamic flow variables on the acoustic behavior of the fluid shield are determined. The acoustic tests are aimed at studying the effect of: (1) shield thickness, (2) wrap angle, (3) mass flow and velocity ratios between shield and core streams at constant cycle specific thrust (i.e., mixed velocity), (4) porous plug, and (5) subsonic shield. Shadowgraphs of six nozzle configurations are obtained to understand the plume flowfield features. Static pressure data on suppressor chutes in the core stream (shielded and unshielded) sides and on plug surface are acquired to determine the impact of fluid shield on base drag of the 36-chute suppressor nozzle and the thrust augmentation due to the plug, respectively.

Salikuddin, M.↗

NASA NTRS2005

Results of Aero/Acoustic Tests and Analytical Studies of a Two-Dimensional Eight-Lobe Mixer-Ejector Exhaust Nozzle at Takeoff Conditions

Hot flow aero-acoustic tests were conducted with Pratt & Whitney's High-Speed Civil Transport (HSCT) Mixer-Ejector Exhaust Nozzles by General Electric Aircraft Engines (GEAE) in the GEAE Anechoic Freejet Noise Facility (Cell 41) located in Evendale, Ohio. The tests evaluated the impact of various geometric and design parameters on the noise generated by a two-dimensional (2-D) shrouded, 8-lobed, mixer-ejector exhaust nozzle. The shrouded mixer-ejector provides noise suppression by mixing relatively low energy ambient air with the hot, high-speed primary exhaust jet. Additional attenuation was obtained by lining the shroud internal walls with acoustic panels, which absorb acoustic energy generated during the mixing process. Two mixer designs were investigated, the high mixing "vortical" and aligned flow "axial", along with variations in the shroud internal mixing area ratios and shroud length. The shrouds were tested as hardwall or lined with acoustic panels packed with a bulk absorber. A total of 21 model configurations at 1:11.47 scale were tested. The models were tested over a range of primary nozzle pressure ratios and primary exhaust temperatures representative of typical HSCT aero thermodynamic cycles. Static as well as flight simulated data were acquired during testing. A round convergent unshrouded nozzle was tested to provide an acoustic baseline for comparison to the test configurations. Comparisons were made to previous test results obtained with this hardware at NASA Glenn's 9- by 15-foot low-speed wind tunnel (LSWT). Laser velocimetry was used to investigate external as well as ejector internal velocity profiles for comparison to computational predictions. Ejector interior wall static pressure data were also obtained. A significant reduction in exhaust system noise was demonstrated with the 2-D shrouded nozzle designs.

Harrington, Douglas↗

NASA NTRS2005

Low Noise Exhaust Nozzle Technology Development

NASA and the U.S. aerospace industry have been assessing the economic viability and environmental acceptability of a second-generation supersonic civil transport, or High Speed Civil Transport (HSCT). Development of a propulsion system that satisfies strict airport noise regulations and provides high levels of cruise and transonic performance with adequate takeoff performance, at an acceptable weight, is critical to the success of any HSCT program. The principal objectives were to: 1. Develop a preliminary design of an innovative 2-D exhaust nozzle with the goal of meeting FAR36 Stage III noise levels and providing high levels of cruise performance with a high specific thrust for Mach 2.4 HSCT with a range of 5000 nmi and a payload of 51,900 lbm, 2. Employ advanced acoustic and aerodynamic codes during preliminary design, 3. Develop a comprehensive acoustic and aerodynamic database through scale-model testing of low-noise, high-performance, 2-D nozzle configurations, based on the preliminary design, and 4. Verify acoustic and aerodynamic predictions by means of scale-model testing. The results were: 1. The preliminary design of a 2-D, convergent/divergent suppressor ejector nozzle for a variable-cycle engine powered, Mach 2.4 HSCT was evolved, 2. Noise goals were predicted to be achievable for three takeoff scenarios, and 3. Impact of noise suppression, nozzle aerodynamic performance, and nozzle weight on HSCT takeoff gross weight were assessed.

Majjigi, R. K.↗

NASA NTRS1998

Effect of Installation of Mixer/Ejector Nozzles on the Core Flow Exhaust of High-Bypass-Ratio Turbofan Engines

The aerospace industry is currently investigating the effect of installing mixer/ejector nozzles on the core flow exhaust of high-bypass-ratio turbofan engines. This effort includes both full-scale engine tests at sea level conditions and subscale tests in static test facilities. Subscale model tests are to be conducted prior to full-scale testing. With this approach, model results can be analyzed and compared with analytical predications. Problem areas can then be identified and design changes made and verified in subscale prior to committing to any final design configurations for engine ground tests. One of the subscale model test programs for the integrated mixer/ejector development was a joint test conducted by the NASA Lewis Research Center and Pratt & Whitney Aircraft. This test was conducted to study various mixer/ejector nozzle configurations installed on the core flow exhaust of advanced, high-bypass-ratio turbofan engines for subsonic, commercial applications. The mixer/ejector concept involves the introduction of largescale, low-loss, streamwise vortices that entrain large amounts of secondary air and rapidly mix it with the primary stream. This results in increased ejector pumping relative to conventional ejectors and in more complete mixing within the ejector shroud. The latter improves thrust performance through the efficient energy exchange between the primary and secondary streams. This experimental program was completed in April 1997 in Lewis' CE-22 static test facility. Variables tested included the nozzle area ratio (A9/A8), which ranged from 1.6 to 3.0. This ratio was varied by increasing or decreasing the nozzle throat area, A8. Primary nozzles tested included both lobed mixers and conical primaries. These configurations were tested with and without an outer shroud, and the shroud position was varied by inserting spacers in it. In addition, data were acquired with and without secondary flow.

Harrington, Douglas E.↗