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Liquid rocket engine injectors

The injector in a liquid rocket engine atomizes and mixes the fuel with the oxidizer to produce efficient and stable combustion that will provide the required thrust without endangering hardware durability. Injectors usually take the form of a perforated disk at the head of the rocket engine combustion chamber, and have varied from a few inches to more than a yard in diameter. This monograph treats specifically bipropellant injectors, emphasis being placed on the liquid/liquid and liquid/gas injectors that have been developed for and used in flight-proven engines. The information provided has limited application to monopropellant injectors and gas/gas propellant systems. Critical problems that may arise during injector development and the approaches that lead to successful design are discussed.

G S Gill↗

Evaluation of Geopolymer Concrete for Rocket Test Facility Flame Deflectors

The current paper presents results from a combined research effort by Louisiana Tech University (LTU) and NASA Stennis Space Center (SSC) to develop a new alumina-silicate based cementitious binder capable of acting as a high performance refractory material with low heat ablation rate and high early mechanical strength. Such a binder would represent a significant contribution to NASA's efforts to develop a new generation of refractory 'hot face' liners for liquid or solid rocket plume environments. This project was developed as a continuation of on-going collaborations between LTU and SSC, where test sections of a formulation of high temperature geopolymer binder were cast in the floor and walls of Test Stand E-1 Cell 3, an active rocket engine test stand flame trench. Additionally, geopolymer concrete panels were tested using the NASA-SSC Diagnostic Test Facility (DTF) thruster, where supersonic plume environments were generated on a 1ft wide x 2ft long x 6 inch deep refractory panel. The DTF operates on LOX/GH2 propellants producing a nominal thrust of 1,200 lbf and the combustion chamber conditions are Pc=625psig, O/F=6.0. Data collected included high speed video of plume/panel area and surface profiles (depth) of the test panels measured on a 1-inch by 1-inch giving localized erosion rates during the test. Louisiana Tech conducted a microstructure analysis of the geopolymer binder after the testing program to identify phase changes in the material.

Allgood, Daniel C.↗

Simplex turbopump design

Turbomachinery used in liquid rocket engines typically are composed of complex geometries made from high strength-to-weight super alloys and have long design and fabrication cycle times (3 to 5 years). A simple, low-cost turbopump is being designed in-house to demonstrate the ability to reduce the overall cost to $500K and compress life cycle time to 18 months. The simplex turbopump was designed to provide a discharge pressure of 1500 psia of liquid oxygen at 90 lbm/s. The turbine will be powered by gaseous oxygen. This eliminates the need for an inter-propellant seal typically required to separate the fuel-rich turbine gases from the liquid oxygen pump components. Materials used in the turbine flow paths will utilize existing characterized metals at 800 deg R that are compatible with a warm oxygen environment. This turbopump design would be suitable for integration with a 40 K pound thrust hybrid motor that provides warm oxygen from a tapped-off location to power the turbine. The preliminary and detailed analysis was completed in a year by a multiple discipline, concurrent engineering team. Manpower, schedule, and cost data were tracked during the process for a comparison to the initial goal. The Simplex hardware is the procurement cycle with the expectation of the first test to occur approximately 1.5 months behind the original schedule goal.

Marsh, Matt↗

Subscale Injector Testing to Support Ares Engines Development

The J-2X and RS-68B rocket engines are being developed for NASA's Ares I and Ares V launch vehicles. In support of the development of these engines, hot-fire testing on subscale coaxial injectors has been performed at NASA s Marshall Space Flight Center (MSFC) to evaluate performance data relative to injector type, liquid oxygen (LOX) post tip design features, element density and various operating conditions. Shear coaxial injectors with element densities of 1.1, 1.6, and 2.3 elements/in2 and a swirl coaxial injector with element density of 1.6 elements/in2 were evaluated at conditions relevant to the Ares applications. Chamber pressures with oxygen/hydrogen propellants ranged from 815-1630 psig with mixture ratios ranging from 4.7-6.9. Fuel manifold inlet temperatures were varied from 90 to 270 R. Shear coaxial LOX post tip thicknesses ranged from 0.006 in. to 0.0175 in. Modular, water cooled, calorimeter chamber assemblies were used to provide heating rate data and evaluate the effects of characteristic length (L*). Performance was evaluated relative to the resulting characteristic velocity (C*) efficiency. Testing with both the 2.3 and 1.1 elements/in2 shear coaxial injectors demonstrated no improvement in performance of the "thin" tip configuration versus the "thick" tip configuration. The loss in chamber pressure and associated performance loss seen in previous testing at low fuel temperatures could not be reliably repeated, indicating that this loss is not the result of a fluidic process in the injector elements. Further, no performance loss could be demonstrated once a faceplate seal specifically designed for operation with low temperature hydrogen was implemented in the 1.1 elements/sq in shear coaxial injector. Results for the 1.6 elements/sq in swirl injector at cold fuel temperatures showed performance higher than both the 1.6 elements/in2 shear coaxial injector and the 2.3 elements/in2 shear coaxial injector.

Protz, Christopher↗

Two-Phase Convection Heat Transfer Correlations for Liquid Hydrogen Pipe Chilldown

Recently, heat transfer correlations based on liquid nitrogen (LN2) and liquid hydrogen (LH2) pipe quenching data were developed to improve the predictive accuracy of lumped node codes like SINDA/FLUINT and the Generalized Fluid System Simulation Program (GFSSP). After implementing these correlations into both programs, updated model runs showed strong improvement in LN2 pipe chilldown modeling but only modest improvement in LH2 modeling. Due to large differences in thermal and fluid properties between the two fluids, results indicated a need to develop a separate set of LH2-only correlations to improve the accuracy of the simulations. This paper presents a new set of two-phase convection heat transfer correlations based on LH2 pipe quenching data. A correlation to predict the bulk vapor temperature was developed after analysis showed that high amounts of thermal nonequilibrium of the liquid and vapor phases occurred during film boiling of LH2. Implemented in a numerical model, the new correlations achieve a mean absolute error of 19.5 K in the predicted wall temperature when compared to recent LH2 pipe chilldown data, an improvement of 40% over recent GFSSP predictions. This correlation set can be implemented in simulations of the transient LH2 chilldown process. Such simulations are useful for predicting the chilldown time and boil-off mass of LH2 for applications such as the transfer of LH2 from a ground storage tank to the rocket vehicle propellant tank, or through a rocket engine feedline during engine startup.

critical heat flux↗

Hydrocarbon Rocket Technology Impact Forecasting

Ever since the Apollo program ended, the development of launch propulsion systems in the US has fallen drastically, with only two new booster engine developments, the SSME and the RS-68, occurring in the past few decades.1 In recent years, however, there has been an increased interest in pursuing more effective launch propulsion technologies in the U.S., exemplified by the NASA Office of the Chief Technologist s inclusion of Launch Propulsion Systems as the first technological area in the Space Technology Roadmaps2. One area of particular interest to both government agencies and commercial entities has been the development of hydrocarbon engines; NASA and the Air Force Research Lab3 have expressed interest in the use of hydrocarbon fuels for their respective SLS Booster and Reusable Booster System concepts, and two major commercially-developed launch vehicles SpaceX s Falcon 9 and Orbital Sciences Antares feature engines that use RP-1 kerosene fuel. Compared to engines powered by liquid hydrogen, hydrocarbon-fueled engines have a greater propellant density (usually resulting in a lighter overall engine), produce greater propulsive force, possess easier fuel handling and loading, and for reusable vehicle concepts can provide a shorter turnaround time between launches. These benefits suggest that a hydrocarbon-fueled launch vehicle would allow for a cheap and frequent means of access to space.1 However, the time and money required for the development of a new engine still presents a major challenge. Long and costly design, development, testing and evaluation (DDT&E) programs underscore the importance of identifying critical technologies and prioritizing investment efforts. Trade studies must be performed on engine concepts examining the affordability, operability, and reliability of each concept, and quantifying the impacts of proposed technologies. These studies can be performed through use of the Technology Impact Forecasting (TIF) method. The Technology Impact Forecasting method is a normative forecasting technique that allows the designer to quantify the effects of adding new technologies on a given design. This method can be used to assess and identify the necessary technological improvements needed to close the gap that exists between the current design and one that satisfies all constraints imposed on the design. The TIF methodology allows for more design knowledge to be brought to the earlier phases of the design process, making use of tools such as Quality Function Deployments, Morphological Matrices, Response Surface Methodology, and Monte Carlo Simulations.2 This increased knowledge allows for more informed decisions to be made earlier in the design process, resulting in shortened design cycle time. This paper will investigate applying the TIF method, which has been widely used in aircraft applications, to the conceptual design of a hydrocarbon rocket engine. In order to reinstate a manned presence in space, the U.S. must develop an affordable and sustainable launch capability. Hydrocarbon-fueled rockets have drawn interest from numerous major government and commercial entities because they offer a low-cost heavy-lift option that would allow for frequent launches1. However, the development of effective new hydrocarbon rockets would likely require new technologies in order to overcome certain design constraints. The use of advanced design methods, such as the TIF method, enables the designer to identify key areas in need of improvement, allowing one to dial in a proposed technology and assess its impact on the system. Through analyses such as this one, a conceptual design for a hydrocarbon-fueled vehicle that meets all imposed requirements can be achieved.

Stuber, Eric↗

LOX/hydrocarbon rocket engine analytical design methodology development and validation. Volume 1: Executive summary and technical narrative

During the past three decades, an enormous amount of resources were expended in the design and development of Liquid Oxygen/Hydrocarbon and Hydrogen (LOX/HC and LOX/H2) rocket engines. A significant portion of these resources were used to develop and demonstrate the performance and combustion stability for each new engine. During these efforts, many analytical and empirical models were developed that characterize design parameters and combustion processes that influence performance and stability. Many of these models are suitable as design tools, but they have not been assembled into an industry-wide usable analytical design methodology. The objective of this program was to assemble existing performance and combustion stability models into a usable methodology capable of producing high performing and stable LOX/hydrocarbon and LOX/hydrogen propellant booster engines.

Pieper, Jerry L.↗

NASA's Space Launch System: Progress Report

NASA and its commercial industry team achieved significant progress in 2016 in manufacturing and testing of the Block 1 vehicle for the first launch of the Space Launch System (SLS). Test and flight article hardware for the liquid hydrogen fuel tank as well as the engine section for the core stage were completed at Michoud Assembly Facility (MAF) in New Orleans. Test stands neared completion at Marshall Space Flight Center for the propellant tanks, engine section, intertank and payload section. Stennis Space Center completed major structural renovations on the B2 test stand, where the core stage "green run" test program will be conducted. The SLS team completed a hotfire test series at Stennis to successfully demonstrate the ability of the RS-25 engine to operate under SLS environments and performance conditions. The team also test fired the second qualification five-segment solid rocket motor and cast the first six motor segments for the first SLS mission. The Interim Cryogenic Propulsion Stage (ICPS) test article was delivered to Marshall for structural tests, and work is nearly finished on the flight stage. Flight software testing completed at Marshall included power quality and command and data handling. In 2017, that work continues. SLS completed Preliminary Design Review (PDR) on the Exploration Upper Stage (EUS), a powerful, human-rated spacecraft that will propel explorers to cis-lunar space. In 2017, hardware will continue to be integrated at MAF for core stage structural test articles and the first two operational flights. RS-25 hotfire testing will continue to explore engine performance, as well as test flight-like software and four new Engine Controller Units (ECUs) for the first mission. Production of development components for a more affordable RS-25 design is underway. Core stage structural test articles have begun arriving at Marshall. While engineering challenges typical of a new development are possible, SLS is working toward launch readiness in late 2018. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before first flight

Cook, Jerry↗

Liquid Rocket Booster (LRB) for the Space Transportation System (STS) systems study. Appendix F: Performance and trajectory for ALS/LRB launch vehicles

By simply combining two baseline pump-fed LOX/RP-1 Liquid Rocket Boosters (LRBs) with the Denver core, a launch vehicle (Option 1 Advanced Launch System (ALS)) is obtained that can perform both the 28.5 deg (ALS) mission and the polar orbit ALS mission. The Option 2 LRB was obtained by finding the optimum LOX/LH2 engine for the STS/LRB reference mission (70.5 K lb payload). Then this engine and booster were used to estimate ALS payload for the 28.5 deg inclination ALS mission. Previous studies indicated that the optimum number of STS/LRB engines is four. When the engine/booster sizing was performed, each engine had 478 K lb sea level thrust and the booster carried 625,000 lb of useable propellant. Two of these LRBs combined with the Denver core provided a launch vehicle that meets the payload requirements for both the ALS and STS reference missions. The Option 3 LRB uses common engines for the cores and boosters. The booster engines do not have the nozzle extension. These engines were sized as common ALS engines. An ALS launch vehicle that has six core engines and five engines per booster provides 109,100 lb payload for the 28.5 deg mission. Each of these LOX/LH2 LRBs carries 714,100 lb of useable propellant. It is estimated that the STS/LRB reference mission payload would be 75,900 lb.

Source record↗

Solid Hydrogen Formed for Atomic Propellants

Several experiments on the formation of solid hydrogen particles in liquid helium were recently conducted at the NASA Glenn Research Center at Lewis Field. The solid hydrogen experiments are the first step toward seeing these particles and determining their shape and size. The particles will ultimately store atoms of boron, carbon, or hydrogen, forming an atomic propellant. Atomic propellants will allow rocket vehicles to carry payloads many times heavier than possible with existing rockets or allow them to be much smaller and lighter. Solid hydrogen particles are preferred for storing atoms. Hydrogen is generally an excellent fuel with a low molecular weight. Very low temperature hydrogen particles (T < 4 K) can prevent the atoms from recombining, making it possible for their lifetime to be controlled. Also, particles that are less than 1 mm in diameter are preferred because they can flow easily into a pipe when suspended in liquid helium. The particles and atoms must remain at this low temperature until the fuel is introduced into the engine combustion (or recombination) chamber. Experiments were, therefore, planned to look at the particles and observe their formation and any changes while in liquid helium.

Palaszewski, Bryan A.↗

Investigation of Impinging Stream Vortex Chamber Concepts for Liquid Rocket Engine Applications

This paper addresses the progress of technology development of a laser ignition system at NASA Marshall Spac Flight Center (MSFC). Initial hot-fire tests in a small-scale rocket chamber at MSFC have demonstrated the dual pulse laser-induced spark (DPLIS) technique, which has an advantage over existing single-pulse laser ignition techniques in that it can be optimized in its laser pulse format to maximize the initial plasma volume, the plasm: lifetime, as well as the flame kernel growth rate. The distribution of the total laser energy into two separate pulse also lowers the peak power that would need to be sent through fiber optics to the combustion chamber, making the implementation of this technique more practical than other single-pulse techniques. A first generation prototype of an optic fiber-coupled laser ignition system will be tested a rocket chamber with RP-1/GOX and GH2/GOX propellants systems. Other relevant technology, such as optical windows, flight-qualified laser system etc. will be discussed in this paper.

Trinh, Huu P.↗

Advanced space engine preliminary design

Analysis and design of an optimum LO2/LH2, combustion topping cycle, 88,964 Newtons (20,000-pound) thrust, liquid rocket engine was conducted. The design selected is well suited to high-energy, upper-stage engine applications such as the Space Tug and embodies features directed toward optimization of vehicle performance. A configuration selection was conducted based on prior Air Force Contracts, and additional criteria for optimum stage performance. Following configuration selection, analyses and design of the major components and engine systems were conducted to sufficient depth to provide layout drawings suitable for subsequent detailing. In addition, engine packaging to a common interface and a retractable nozzle concept were defined. Alternative development plans and related costs were also established. The design embodies high-performance, low-weight, low NPSH requirements (saturated propellant inlet conditions at start), idle-mode operation, and autogenous pressurization. The design is the result of the significant past and current LO2/LH2 technology efforts of the NASA centers and the Air Force, as well as company-funded programs.

Zachary, A. T.↗

A fast sampling device for the mass spectrometric analysis of liquid rocket engine exhaust

The design of a device to obtain compositional data on rocket exhaust by direct sampling of reactive flow exhausts into a mass spectrometer is presented. Sampling at three stages differing in pressure and orifice angle and diameter is possible. Results of calibration with pure gases and gas mixtures are erratic and of unknown accuracy for H2, limiting the usefulness of the apparatus for determining oxidizer/fuel ratios from combustion product analysis. Deposition effects are discussed, and data obtained from rocket exhaust spectra are analyzed to give O/F ratios and mixture ratio distribution. The O/F ratio determined spectrometrically is insufficiently accurate for quantitative comparison with cold flow data. However, a criterion for operating conditions with improved mixing of fuel and oxidizer which is consistent with cold flow results may be obtained by inspection of contour plots. A chemical inefficiency in the combustion process when oxidizer is in excess is observed from reactive flow measurements. Present results were obtained with N2O4/N2H4 propellants.

Ryason, P. R.↗

Small rocket research and technology

Small chemical rockets are used on nearly all space missions. The small rocket program provides propulsion technology for civil and government space systems. Small rocket concepts are developed for systems which encompass reaction control for launch and orbit transfer systems, as well as on-board propulsion for large space systems and earth orbit and planetary spacecraft. Major roles for on-board propulsion include apogee kick, delta-V, de-orbit, drag makeup, final insertions, north-south stationkeeping, orbit change/trim, perigee kick, and reboost. The program encompasses efforts on earth-storable, space storable, and cryogenic propellants. The earth-storable propellants include nitrogen tetroxide (NTO) as an oxidizer with monomethylhydrazine (MMH) or anhydrous hydrazine (AH) as fuels. The space storable propellants include liquid oxygen (LOX) as an oxidizer with hydrazine or hydrocarbons such as liquid methane, ethane, and ethanol as fuels. Cryogenic propellants are LOX or gaseous oxygen (GOX) as oxidizers and liquid or gaseous hydrogen as fuels. Improved performance and lifetime for small chemical rockets are sought through the development of new predictive tools to understand the combustion and flow physics, the introduction of high temperature materials to eliminate fuel film cooling and its associated combustion inefficiency, and improved component designs to optimize performance. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Results indicate that modeling of the injector and combustion process in small rockets needs improvement. High temperature materials require the development of fabrication processes, a durability data base in both laboratory and rocket environments, and basic engineering property data such as strength, creep, fatigue, and work hardening properties at both room and elevated temperature. Promising materials under development include iridium-coated rhenium and a ceramic composite of mixed hafnium carbide and tantalum carbide reinforced with graphite fibers.

Schneider, Steven↗

Demonstration of Oxygen and Carbon Monoxide Propellants for Mars Missions

Currently, proposed planetary exploration missions must be small, with low costs and a short development time. Relatively high-risk technologies are being accepted for such missions if they meet these guidelines. For a Mars sample-return mission, one of the higher risk technologies is the use of return propellants produced from indigenous materials such as the Martian atmosphere. This consists of 96 percent carbon dioxide, which can be processed into oxygen and carbon monoxide. This year, the NASA Lewis Research Center completed the experimental evaluation and subscale technology development of an oxygen/carbon monoxide propellant combination. Previous research included ignition characterization, combustion performance, and heat transfer characterization with gaseous propellants at room temperature. In this year s tests, we studied the ignition characteristics and combustion of oxygen and carbon monoxide at near liquid temperatures. The mixture ratio boundaries for oxygen and carbon monoxide were determined as a function of propellant temperature in a spark torch igniter. With both propellants at room temperature, the ignition range was between 0.50 and 1.44; and with both propellants chilled to near-liquid temperatures, it was between 2.4 and 3.1. Statistical analysis of the mean value of the ignition boundaries provided models that describe the combination of oxygen temperature, carbon monoxide temperature, and mixture ratio that resulted in ignition. This range is the larger boxed area shown in the figure. The smaller boxed area indicates the range at which there is a 90-percent confidence that ignition will occur. The relatively small range at only 90-percent confidence indicates that using the oxygen/carbon monoxide combination as its own ignition source may not be the best design for a remote engine operating on Mars. Tests also were performed in a simulated small rocket engine that used oxygen/hydrogen combustion gases as the ignition source for oxygen/carbon monoxide. In these experiments, the oxygen/carbon monoxide was successfully ignited in eight of eight tests at a mixture ratio of 0.52. In addition, the oxygen/carbon monoxide maintained steady combustion after the oxygen/hydrogen ignition source was removed, verifying that the oxygen/carbon monoxide rocket engine should continue to be included in mission plans as return propulsion from Mars.

Linne, Diane L.↗

Nuclear Engine System Simulation (NESS). Volume 1: Program user's guide

A Nuclear Thermal Propulsion (NTP) engine system design analysis tool is required to support current and future Space Exploration Initiative (SEI) propulsion and vehicle design studies. Currently available NTP engine design models are those developed during the NERVA program in the 1960's and early 1970's and are highly unique to that design or are modifications of current liquid propulsion system design models. To date, NTP engine-based liquid design models lack integrated design of key NTP engine design features in the areas of reactor, shielding, multi-propellant capability, and multi-redundant pump feed fuel systems. Additionally, since the SEI effort is in the initial development stage, a robust, verified NTP analysis design tool could be of great use to the community. This effort developed an NTP engine system design analysis program (tool), known as the Nuclear Engine System Simulation (NESS) program, to support ongoing and future engine system and stage design study efforts. In this effort, Science Applications International Corporation's (SAIC) NTP version of the Expanded Liquid Engine Simulation (ELES) program was modified extensively to include Westinghouse Electric Corporation's near-term solid-core reactor design model. The ELES program has extensive capability to conduct preliminary system design analysis of liquid rocket systems and vehicles. The program is modular in nature and is versatile in terms of modeling state-of-the-art component and system options as discussed. The Westinghouse reactor design model, which was integrated in the NESS program, is based on the near-term solid-core ENABLER NTP reactor design concept. This program is now capable of accurately modeling (characterizing) a complete near-term solid-core NTP engine system in great detail, for a number of design options, in an efficient manner. The following discussion summarizes the overall analysis methodology, key assumptions, and capabilities associated with the NESS presents an example problem, and compares the results to related NTP engine system designs. Initial installation instructions and program disks are in Volume 2 of the NESS Program User's Guide.

Pelaccio, Dennis G.↗

A rapid method for optimization of the rocket propulsion system for single-stage-to-orbit vehicles

A rapid analytical method for the optimization of rocket propulsion systems is presented for a vertical take-off, horizontal landing, single-stage-to-orbit launch vehicle. This method utilizes trade-offs between propulsion characteristics affecting flight performance and engine system mass. The performance results from a point-mass trajectory optimization program are combined with a linearized sizing program to establish vehicle sizing trends caused by propulsion system variations. The linearized sizing technique was developed for the class of vehicle systems studied herein. The specific examples treated are the optimization of nozzle expansion ratio and lift-off thrust-to-weight ratio to achieve either minimum gross mass or minimum dry mass. Assumed propulsion system characteristics are high chamber pressure, liquid oxygen and liquid hydrogen propellants, conventional bell nozzles, and the same fixed nozzle expansion ratio for all engines on a vehicle.

Eldred, C. H.↗

A Design Tool for Liquid Rocket Engine Injectors

A practical design tool which emphasizes the analysis of flowfields near the injector face of liquid rocket engines has been developed and used to simulate preliminary configurations of NASA's Fastrac and vortex engines. This computational design tool is sufficiently detailed to predict the interactive effects of injector element impingement angles and points and the momenta of the individual orifice flows and the combusting flow which results. In order to simulate a significant number of individual orifices, a homogeneous computational fluid dynamics model was developed. To describe sub- and supercritical liquid and vapor flows, the model utilized thermal and caloric equations of state which were valid over a wide range of pressures and temperatures. The model was constructed such that the local quality of the flow was determined directly. Since both the Fastrac and vortex engines utilize RP-1/LOX propellants, a simplified hydrocarbon combustion model was devised in order to accomplish three-dimensional, multiphase flow simulations. Such a model does not identify drops or their distribution, but it does allow the recirculating flow along the injector face and into the acoustic cavity and the film coolant flow to be accurately predicted.

Farmer, R.↗