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NASA NTRS2002

Advanced Engine Cycles Analyzed for Turbofans With Variable-Area Fan Nozzles Actuated by a Shape Memory Alloy

Advanced, large commercial turbofan engines using low-fan-pressure-ratio, very high bypass ratio thermodynamic cycles can offer significant fuel savings over engines currently in operation. Several technological challenges must be addressed, however, before these engines can be designed. To name a few, the high-diameter fans associated with these engines pose a significant packaging and aircraft installation challenge, and a large, heavy gearbox is often necessary to address the differences in ideal operating speeds between the fan and the low-pressure turbine. Also, the large nacelles contribute aerodynamic drag penalties and require long, heavy landing gear when mounted on conventional, low wing aircraft. Nevertheless, the reduced fuel consumption rates of these engines are a compelling economic incentive, and fans designed with low pressure ratios and low tip speeds offer attractive noise-reduction benefits. Another complication associated with low-pressure-ratio fans is their need for variable flow-path geometry. As the design fan pressure ratio is reduced below about 1.4, an operational disparity is set up in the fan between high and low flight speeds. In other words, between takeoff and cruise there is too large a swing in several key fan parameters-- such as speed, flow, and pressure--for a fan to accommodate. One solution to this problem is to make use of a variable-area fan nozzle (VAFN). However, conventional, hydraulically actuated variable nozzles have weight, cost, maintenance, and reliability issues that discourage their use with low-fan-pressure-ratio engine cycles. United Technologies Research, in cooperation with NASA, is developing a revolutionary, lightweight, and reliable shape memory alloy actuator system that can change the on-demand nozzle exit area by up to 20 percent. This "smart material" actuation technology, being studied under NASA's Ultra-Efficient Engine Technology (UEET) Program and Revolutionary Concepts in Aeronautics (RevCon) Program, has the potential to enable the next generation of efficient, quiet, very high bypass ratio turbofans. NASA Glenn Research Center's Propulsion Systems Analysis Office, along with NASA Langley Research Center's Systems Analysis Branch, conducted an independent analytical assessment of this new technology to provide strategic guidance to UEET and RevCon. A 2010-technology-level high-spool engine core was designed for this evaluation. Two families of low-spool components, one with and one without VAFN's, were designed to operate with the core. This "constant core" approach was used to hold most design parameters constant so that any performance differences between the VAFN and fixed nozzle cycles could be attributed to the VAFN technology alone. In this manner, the cycle design regimes that offer a performance payoff when VAFN's are used could be identified. The NASA analytical model of a performance-optimized VAFN turbofan with a fan pressure ratio of 1.28 is shown. Mission analyses of the engines were conducted using the notional, long-haul, advanced commercial twinjet shown. A high wing design was used to accommodate the large high-bypassratio engines. The mission fuel reduction benefit of very high bypass shape-memory-alloy VAFN aircraft was calculated to be 8.3 percent lower than a moderate bypass cycle using a conventional fixed nozzle. Shape-memory-alloy VAFN technology is currently under development in NASA's UEET and RevCon Programs.

Berton, Jeffrey J.↗

NASA NTRS2005

Transient Three-Dimensional Analysis of Nozzle Side Load in Regeneratively Cooled Engines

Three-dimensional numerical investigations on the start-up side load physics for a regeneratively cooled, high-aspect-ratio nozzle were performed. The objectives of this study are to identify the three-dimensional side load physics and to compute the associated aerodynamic side load using an anchored computational methodology. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet condition based on an engine system simulation. Computations were performed for both the adiabatic and cooled walls in order to understand the effect of boundary conditions. Finite-rate chemistry was used throughout the study so that combustion effect is always included. The results show that three types of shock evolution are responsible for side loads: generation of combustion wave; transitions among free-shock separation, restricted-shock separation, and simultaneous free-shock and restricted shock separations; along with oscillation of shocks across the lip. Wall boundary conditions drastically affect the computed side load physics: the adiabatic nozzle prefers free-shock separation while the cooled nozzle favors restricted-shock separation, resulting in higher peak side load for the cooled nozzle than that of the adiabatic nozzle. By comparing the computed physics with those of test observations, it is concluded that cooled wall is a more realistic boundary condition, and the oscillation of the restricted-shock separation flow pattern across the lip along with its associated tangential shock motion are the dominant side load physics for a regeneratively cooled, high aspect-ratio rocket engine.

Wang, Ten-See↗

NASA NTRS2006

The Design of a High-Q, MACH-5 Nozzle for the Langley 8-Foot HTT

A new nozzle has ben designed for the NASA Langley Research Center 8-Foot High Temperature Tunnel. The new nozzle was designed with a Mach-5 exit flow at a Mach-5 flight-enthalpy test condition and has a smaller throat area than the existing Mach-5 nozzle which significantly increases the range of dynamic pressures that can be achieved in the facility. The nozzle was designed using the NASA Langley IMOCND computer program which solves the potential equation using the classical method of characteristics. Several axisymmetric nozzle contours were generated and evaluated using viscous computational fluid dynamics. A number of items were considered in the evaluation, including flow uniformity, thermal and structural design, manufacturing schedule and cost. Once the final contour was selected, studies were done to determine the effects of manufacturing irregularities (steps and cavities at joints). These studies were done to develop manufacturing specifications and assembly tolerances.

Gaffey, Richard L., Jr.↗

NASA NTRS2006

Acoustic Efficiency of Azimuthal Modes in Jet Noise Using Chevron Nozzles

The link between azimuthal modes in jet turbulence and in the acoustic sound field has been examined in cold, round jets. Chevron nozzles, however, impart an azimuthal structure on the jet with a shape dependent on the number, length and penetration angle of the chevrons. Two particular chevron nozzles, with 3 and 4 primary chevrons respectively, and a round baseline nozzle are compared at both cold and hot jet conditions to determine how chevrons impact the modal structure of the flow and how that change relates to the sound field. The results show that, although the chevrons have a large impact on the azimuthal shape of the mean axial velocity, the impact of chevrons on the azimuthal structure of the fluctuating axial velocity is small at the cold jet condition and smaller still at the hot jet condition. This is supported by results in the azimuthal structure of the sound field, which also shows little difference in between the two chevron nozzles and the baseline nozzle in the distribution of energy across the azimuthal modes measured.

Brown, Clifford A.↗

NASA NTRS1956

Exhaust Nozzles for Supersonic Flight with Turbojet Engines

Good internal performance over a wide range of flight conditions can be obtained with either a plug nozzle or a variable ejector nozzle that can provide a divergent shroud at high pressure ratios. For both the ejector and the plug nozzle, external flow can sometimes cause serious drag losses and, for some plug-nozzle installations, external flow can cause serious internal performance losses. Plug-nozzle cooling and design of the secondary-air-flow systems for ejectors were also considered .

Shillito, Thomas B.↗

NASA NTRS1948

Preliminary Results of Nene II Engine Altitude-chamber Performance Investigation: Altitude Performance using 18.00-inch-diameter Jet Nozzle - 3

An investigation is being conducted to determine the altitude performance characteristics of the Nene II engine and its components. The present paper presents the preliminary results obtained using jet nozzle 18.00 inches in diameter, with an area equal to 92.2 percent of the area of the standard jet nozzle for this engine. The experimental results presented are for conditions simulating altitudes from 20,000 to 60,000 feet and ram-pressure ratios from 1.1 to 3.5. These ram-pressure ratios correspond to flight Mach numbers between 0.374 and 1.466. Data obtained with the 18.00 inch-diameter jet nozzle and corrected to standard sea-level conditions showed substantially the same trends with altitude as the data previously obtained with an 18.75-inch-diameter nozzle and with an 18.41-inch-diameter nozzle. Jet thrust, air consumption, and fuel consumption, corrected to standard sea-level conditions, increased rapidly with increasing ram-pressure ratio. In general, corrected net thrust specific fuel consumption increased with increase in ram-pressure ratio. Corrected net thrust decreased with an increase in ram-pressure ratio at an engine speed of 8000 rpm. At corrected engine speeds between 8000 and 10,800 rpm, net thrust first decreased with an increase in ram-pressure ratio and then increased with further increase in ram pressure ratio; at corrected engine speeds above 10,800 rpm, net thrust increased continuously with increase in ram-pressure ratio. Tail-pipe temperature decreased with an increase in ram-pressure ratio.

Grey, Ralph E.↗

NASA NTRS2009

Shape memory alloy actuated adaptive exhaust nozzle for jet engine

The proposed adaptive exhaust nozzle features an innovative use of the shape memory alloy (SMA) actuators for actively control of the opening area of the exhaust nozzle for jet engines. The SMA actuators remotely control the opening area of the exhaust nozzle through a set of mechanism. An important advantage of using SMA actuators is the reduction of weight of the actuator system for variable area exhaust nozzle. Another advantage is that the SMA actuator can be activated using the heat from the exhaust and eliminate the need of other energy source. A prototype has been designed and fabricated. The functionality of the proposed SMA actuated adaptive exhaust nozzle is verified in the open-loop tests.

Song, Gangbing↗

NASA NTRS2009

Integrity of the Plasma Magnetic Nozzle

This report examines the physics governing certain aspects of plasma propellant flow through a magnetic nozzle, specifically the integrity of the interface between the plasma and the nozzle s magnetic field. The injection of 100s of eV plasma into a magnetic flux nozzle that converts thermal energy into directed thrust is fundamental to enabling 10 000s of seconds specific impulse and 10s of kW/kg specific power piloted interplanetary propulsion. An expression for the initial thickness of the interface is derived and found to be approx.10(exp -2) m. An algorithm is reviewed and applied to compare classical resistivity to gradient-driven microturbulent (anomalous) resistivity, in terms of the spatial rate and time integral of resistive interface broadening, which can then be related to the geometry of the nozzle. An algorithm characterizing plasma temperature, density, and velocity dependencies is derived and found to be comparable to classical resistivity at local plasma temperatures of approx. 200 eV. Macroscopic flute-mode instabilities in regions of "adverse magnetic curvature" are discussed; a growth rate formula is derived and found to be one to two e-foldings of the most unstable Rayleigh-Taylor (RT) mode. After establishing the necessity of incorporating the Hall effect into Ohm s law (allowing full Hall current to flow and concomitant plasma rotation), a critical nozzle length expression is derived in which the interface thickness is limited to about 1 ion gyroradius.

Gerwin, Richard A.↗

NASA NTRS2010

Fluid Structure Interaction in a Cold Flow Test and Transient CFD Analysis of Out-of-Round Nozzles

This viewgraph presentation describes two nozzle fluid flow interactions. They include: 1) Cold flow nozzle tests with fluid-structure interaction at nozzle separated flow; and 2) CFD analysis for nozzle flow and side loads of nozzle extensions with various out-of-round cases.

Ruf, Joseph↗

NASA NTRS2010

Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles

The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads at a high altitude, with an anchored computational methodology. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests, and deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four different degrees of ovalization: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation-line-jump is the peak side load physics for the round, slightly our-of-round, and more out-of-round cases, and the peak side load increases as the degree of out-of-roundness increases. For the significantly out-of-round nozzle, however, the peak side load reduces to comparable to that of the round nozzle and the separation line jump is not the peak side load physics. The counter-intuitive result of the significantly out-of-round case is found to be related to a side force reduction mechanism that splits the effect of the separation-line-jump into two parts, not only in the circumferential direction and most importantly in time.

Wang, Ten-See↗

NASA NTRS2002

Thermal Analysis of Compressible CO2 Flow for PFE TeSS Nozzle of Fire Detection System

A thermal analysis of the compressible CO2 flow for the Portable Fire Extinguisher (PFE) system has been performed. A SINDA/FLUINT model has been developed for this analysis. The model includes the PFE tank and the TeSS nozzle, and both have initial temperature of 72 F. In order to investigate the thermal effect on the nozzle due to discharging CO2, the PFE TeSS nozzle pipe has been divided into three segments. This model also includes heat transfer predictions for PFE tank inner and outer wall surfaces. The simulation results show that the CO2 discharge rates have fulfilled the minimum flow requirements that the PFE system discharges 3.0 Ibm CO2 in 10 seconds and 5.5 Ibm of CO2 in 45 seconds during its operation. At 45 seconds, the PFE tank wall temperature is 63 F, and the TeSS nozzle cover wall temperatures for the three segments are 47 F, 53 F and 37 F, respectively. Thermal insulation for personal protection is used for the first two segments of the TeSS nozzle. The simulation results also indicate that at 50 seconds, the remaining CO2 in the tank may be near the triple point (gas, liquid and solid) state and, therefore, restricts the flow.

Zhang, Y. Michael↗

NASA NTRS2011

Modeling of Supersonic Film Cooling on the J-2X Nozzle Extension

Supersonic film cooling (SSFC) of nozzles has been used in several liquid rocket engine designs, and is being applied to the nozzle extension (NE) of the J-2X upper stage engine currently under development. Turbine exhaust gas (TEG) is injected tangentially from a manifold along the NE, and provides a thermal barrier from the core nozzle flow for the NE. As the TEG stream mixes with the nozzle flow, the effectiveness of the thermal barrier is reduced. This paper documents computational fluid dynamics (CFD) analysis work performed by NASA Marshall Space Flight Center (MSFC) to model the flow of the TEG through the manifold, into the nozzle, and the subsequent mixing of the TEG stream with the core flow. The geometry and grid of the TEG manifold, structural support ribs, and the NE wall will be shown, and the CFD boundary conditions described. The Loci-CHEM CFD code used in this work will also be briefly described. A unique approach to modeling the combined TEG manifold/thrust chamber assembly (TCA) was employed, as it was not practical to model the entire 360 circumferential range in one simulation. Prior CFD validation work modeling Calspan SSFC experiments in the early 1990s, documented in a previous AIAA paper, will also be briefly discussed. The fluid dynamics of the TEG flow through the manifold, into and between the structural support ribs, and into the nozzlette that feeds the TCA will be described. Significant swirl and non-uniformities are present, which along with the wakes from the ribs, act to degrade the film cooling effectiveness compared to idealized injection of TEG gas. The effect of these flow characteristics on the adiabatic wall temperature profile on the NE will be discussed.

Ruf, Joseph H.↗

NASA NTRS2012

Effect of Initial Condition on Subsonic Jet Noise from Two Rectangular Nozzles

Differences in jet noise data from two small 8:1 aspect ratio nozzles are investigated experimentally. The interiors of the two nozzles are identical but one has a thin-lip at the exit while the has a perpendicular face at the exit (thick-lip). It is found that the thin-lip nozzle is substantially noisier throughout the subsonic Mach number range. As much as 5dB difference in OASPL is noticed around Mj =0.96. Hot-wire measurements are carried out for the characteristics of the exit boundary layer and, overall, the noise difference can be ascribed to differences in the boundary layer state. The boundary layer of the quieter (thick-lip) nozzle goes through transition around M(sub j) =0.25 and at higher M(sub j) it remains "nominally turbulent". In comparison, the boundary layer of the thin-lip nozzle is found to remain "nominally laminar". at high subsonic conditions. The nominally laminar state involves significantly larger turbulence intensities commensurate with the higher radiated noise.

Zaman, K. B. M. Q.↗

NASA NTRS2013

Exhaust Nozzle Plume and Shock Wave Interaction

Fundamental research for sonic boom reduction is needed to quantify the interaction of shock waves generated from the aircraft wing or tail surfaces with the exhaust plume. Both the nozzle exhaust plume shape and the tail shock shape may be affected by an interaction that may alter the vehicle sonic boom signature. The plume and shock interaction was studied using Computational Fluid Dynamics simulation on two types of convergent-divergent nozzles and a simple wedge shock generator. The nozzle plume effects on the lower wedge compression region are evaluated for two- and three-dimensional nozzle plumes. Results show that the compression from the wedge deflects the nozzle plume and shocks form on the deflected lower plume boundary. The sonic boom pressure signature of the wedge is modified by the presence of the plume, and the computational predictions show significant (8 to 15 percent) changes in shock amplitude.

Castner, Raymond S.↗

NASA NTRS2013

Computational Studies of Magnetic Nozzle Performance

An extensive literature review of magnetic nozzle research has been performed, examining previous work, as well as a review of fundamental principles. This has allow us to catalog all basic physical mechanisms which we believe underlie the thrust generation process. Energy conversion mechanisms include the approximate conservation of the magnetic moment adiabatic invariant, generalized hall and thermoelectric acceleration, swirl acceleration, thermal energy transformation into directed kinetic energy, and Joule heating. Momentum transfer results from the interaction of the applied magnetic field with currents induced in the plasma plume., while plasma detachment mechanisms include resistive diffusion, recombination and charge exchange collisions, magnetic reconnection, loss of adiabaticity, inertial forces, current closure, and self-field detachment. We have performed a preliminary study of Hall effects on magnetic nozzle jets with weak guiding magnetic fields and weak expansions (p(sub jet) approx. = P(sub background)). The conclusion from this study is that the Hall effect creates an azimuthal rotation of the plasma jet and, more generally, creates helical structures in the induced current, velocity field, and magnetic fields. We have studied plasma jet expansion to near vacuum without a guiding magnetic field, and are presently including a guiding magnetic field using a resistive MHD solver. This research is progressing toward the implementation of a full generalized Ohm's law solver. In our paper, we will summarize the basic principle, as well as the literature survey and briefly review our previous results. Our most recent results at the time of submittal will also be included. Efforts are currently underway to construct an experiment at the University of Michigan Plasmadynamics and Electric Propulsion Laboratory (PEPL) to study magnetic nozzle physics for a RF-thruster. Our computational study will work directly with this experiment to validate the numerical model, in order to study magnetic nozzle physics and optimize magnetic nozzle design. Preliminary results from the PEPL experiment will also be presented.

Ebersohn, Frans H.↗

NASA NTRS2013

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development during test. While three-dimensional, transient, turbulent, chemically reacting computational fluid dynamics methodology has been demonstrated to capture major side load physics with rigid nozzles, hot-fire tests often show nozzle structure deformation during major side load events, leading to structural damages if structural strengthening measures were not taken. The modeling picture is incomplete without the capability to address the two-way responses between the structure and fluid. The objective of this study is to develop a coupled aeroelastic modeling capability by implementing the necessary structural dynamics component into an anchored computational fluid dynamics methodology. The computational fluid dynamics component is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, while the computational structural dynamics component is developed in the framework of modal analysis. Transient aeroelastic nozzle startup analyses of the Block I Space Shuttle Main Engine at sea level were performed. The computed results from the aeroelastic nozzle modeling are presented.

Wang, Ten-See↗

NASA NTRS2013

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Wang, Ten-See↗

NASA NTRS2014

Coupled CFD-Thermal Analysis of Erosion Patterns Resulting from Nozzle Wedgeouts on the SRTMV-N2

The objective of this analysis was to study the effects of the erosion patterns from the introduction of nozzle flaws machined into the nozzle of the SRTMV-N2 (Solid Rocket Test Motor V Nozzle 2). The SRTMV-N2 motor was a single segment static subscale solid rocket motor used to further develop the RSRMV (Redesigned Solid Rocket Motor V Segment). Two flaws or "wedgeouts" were placed in the nozzle inlet parallel to the ply angles of that section to study erosion effects. One wedgeout was placed in the nose cap region and the other placed in the inlet ring on the opposite side of the bondline, separated 180 degrees circumferentially. A coupled CFD (Computational Fluid Analysis)-thermal iterative analytical approach was utilized at the wedgeouts to analyze the erosion profile during the burn time. The iterative CFD thermal approach was applied at five second intervals throughout the motor burn. The coupled fluid thermal boundary conditions were derived from a steady state CFD solution at the beginning of the interval. The derived heat fluxes were then applied along the surface and a transient thermal solution was developed to characterize the material response over the specified interval. Eroded profiles of each of the nozzle's wedgeouts and the original contour were created at each of the specified intervals. The final iteration of the erosion profile showed that both wedgeouts were "washedout," indicating that the erosion profile of the wedgeout had rejoined the original eroded contour, leaving no trace of the wedgeouts post fire. This analytical assessment agreed with post-fire observations made of the SRTMV-N2 wedgeouts, which noted a smooth eroded contour.

Ables, Catherine↗