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NASA NTRS1991

Langley 8-foot high-temperature tunnel oxygen measurement system

In order to ensure that there is a proper amount of oxygen necessary for sustaining test engine operation for hypersonic propulsion systems testing at the NASA Langley 8-foot high-temperature tunnel, a quickly responding real-time measurement system of test section oxygen concentration has been designed and tested at Langley. It is built around a zirconium oxide-based sensor which develops a voltage proportional to the oxygen partial pressure of the test gas. The voltage signal is used to control the amount of oxygen being injected into the combustor air. The physical operation of the oxygen sensor is described, as well as the sampling system used to extract the test gas from the tunnel test section. Results of laboratory tests conducted to verify sensor accuracy and response time performance are discussed, as well as the final configuration of the system to be installed in the tunnel.

Sprinkle, Danny R.↗

NASA NTRS2010

Igniter Testing and Development for Liquid Oxygen/Liquid Methane (LOX/LCH4) and Liquid Oxygen/Gaseous Hydrogen (LOX/GH2) Injectors

In support of NASA's efforts to advance methane technology for future exploration missions, two different igniter concepts were developed and tested at NASA's Marshall Space Flight Center for ignition of oxygen/methane propellants. The first type of igniter, an impinging injection, spark-initiated torch igniter (impinging igniter), used traditional spark plug technology to produce a small, but very intense, pulsed plasma as the ignition source. The second type of igniter, a microwave-generated plasma igniter (microwave igniter), used a microwave magnetron to produce a continuous, larger-volume plasma as the ignition source. Two new designs for both types of igniters were leveraged off past oxygen/methane igniter designs that were tested at MSFC and documented in a 2008 JANNAF paper. In this most recent work, the two new igniters were to be tested at the component level as well as inside a liquid oxygen/liquid methane (LOX/LCH4) 40-element swirl coaxial injector. Although the microwave igniter achieved ignition in every test, it encountered technical difficulties that prevented it from being tested with the injector. The impinging igniter required several design iterations as well as testing at different mixture ratios and mass flow rates before reliable operation with minimal ignition delay was achieved. The final design of the impinging igniter was successfully tested in the LOX/LCH4 injector. The same igniter was later re-configured and component-tested to demonstrate reliable ignition of oxygen/hydrogen propellants. Future tests of the impinging igniter will include ignition of a LOX/hydrogen two-stage swirl injector, which is one of several injector concepts being tested in the Lunar Lander Descent Engine Test Bed at MSFC. All igniter and injector tests have been funded by the Propulsion & Cryogenics Advanced Development project managed by Glenn Research Center and sponsored by NASA s Exploration Technology Development Program.

Osborne, Robin J.↗

NASA NTRSDate not supplied

Edge Wear of the Advanced Electric Propulsion System Pole Covers

This work summarizes a wear test focused on characterizing the erosion of the edges and side walls of the 12-kW Advanced Electric Propulsion System (AEPS) pole covers as well as the impact of magnetic field strength on component erosion for operation at a discharge voltage of 600 V. Testing was performed with the AEPS Engineering Test Unit 2 (ETU-2) thruster and accumulated approximately 325 hours of operation at the 600 V/12 kW condition with the magnetic field strength set to 75% of its nominal value. Thruster performance was invariant throughout the wear test for all thruster throttle conditions and matched previous measurements at the nominal magnetic field strength. Contrary to past results, inner front pole cover erosion rates were invariant to magnetic field strength at the 600 V/12 kW condition and no erosion was measured on the outer front pole cover. The erosion profile of the downstream inner front pole cover faces was continuous across the cover, indicating no significant change in erosion processes at the pole cover edges. Side wall erosion was only detected on the cathode-facing surfaces of the inner front pole cover and was equal in magnitude to the rates measured on the adjacent downstream edges. Taken together, these results suggest that erosion of the pole cover edges and sidewalls is driven by cathode-borne ions and will ultimately not impact AEPS life estimates.

Hall thrusters↗

NASA NTRSDate not supplied

Edge Wear of the Advanced Electric Propulsion System Pole Covers

This work presents a summary of the first wear test of the 12 kW Advanced Electric Propulsion System (AEPS) focused on characterizing the erosion of the edges and side walls of the thruster pole covers. Testing was performed with the AEPS Engineering Test Unit 2 (ETU-2) thruster and accumulated approximately 325 hours of operation at the 600 V/12 kW condition with the magnetic field strength set to 75% of its nominal value. Thruster performance was invariant throughout the wear test for all thruster throttle conditions and was found to be equal to previous measurements. Contrary to past results, inner front pole cover erosion rates were invariant to magnetic field strength at the 600 V/12 kW condition and no erosion was measured on the outer front pole cover. The erosion profile of the downstream inner front pole cover faces was continuous across the cover indicating no significant change in erosion process at the pole cover edges. Side wall erosion was only detected on the cathode-facing surfaces of the inner front pole cover and was equal in magnitude to the rates measured on the adjacent downstream edges. Taken together, these results suggest that erosion of the pole cover edges and sidewalls is driven by cathode-borne ions and will ultimately not impact AEPS life estimates.

Hall thrusters↗

NASA NTRS2006

Marshall Space Flight Center Autumn 2005

The East Test Area at Marshall Space Flight Center has five major test stands, each of which has two or more test positions, not counting the SSME and RD-180 engine test facilities in the West Test Area. These research and development facilities are capable of testing high pressure pumps, both fuel and oxidizer, injectors, chambers and sea-level engine assemblies, as well as simulating deep space environments in the 12, 15 and 20 foot vacuum chambers. Liquid propellant capabilities are high pressure hydrogen (liquid and gas), methane (liquid and gas), and RP-1 and high pressure LOX. Solid propellant capability includes thrust measurement and firing capability up to 1/6 scale Shuttle SRB segment. In the past six months MSFC supported multiple space access and exploration programs in the previous six months. Major programs were Space Exploration, Shuttle External Tank research, Reusable Solid Rocket Motor (RSRM) development, as well as research programs for NASA and other customers. At Test Stand 115 monopropellant ignition testing was conducted on one position. At the second position multiple ignition/variable burn time cycles were conducted on Vacuum Plasma Spatter (VPS) coated injectors. Each injector received fifty cycles; the propellants were LOX Hydrogen and the ignition source was TEA. Following completion of the monopropellant test series the stand was reconfigured to support ignition testing on a LOX Methane injector system. At TS 116 a thrust stand used to test Booster Separation Motors from the Shuttle SRB system was disassembled and moved from Chemical Systems Division s Coyote Canyon plant to MSFC. The stand was reassembled and readied for BSM testing. Also, a series of tests was run on a Pratt & Whitney Rocketdyne Low Element Density (LED) injector engine. The propellants for this engine are LOX and LH2. At TS 300 the 20 foot vacuum chamber was configured to support hydrogen testing in the Multipurpose Hydrogen Test Bed (MHTB) test article. This testing, which went 24/7 for fourteen consecutive days, demonstrated long duration storage methods intended to minimize losses of propellant in support of the Space Exploration Initiative. The facility is being converted to support similar research using liquid methane. The 12 foot chamber at TS 300 was used to create ascent profiles (both heat and altitude effects) for foam panel testing in support of the Shuttle External Tank program. At TS 500, one position was in build-up to support ATK Thiokol research into the gas dynamics associated with high pressure flow across the propellant joint in segmented solid rocket motors. The testing involves flowing high pressure gas through a 24 motor case. Initial tests will be conducted with simulated aluminum grain, followed by tests using actual propellant. The second position at TS 500 has been in build-up for testing a LOX methane thruster manufactured by KT Engineering. At the Solid Propulsion Test Area (SPTA), the first dual segment 24 solid rocket motor was fired for ATK Thiokol in support of the RSRM program. A new axial thrust measurement stand was designed and fabricated for this testing. Real Time Radiography (RTR) will be deployed to examine nozzle erosion on the next dual segment motor.

Allen, Mike↗

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.↗

NASA NTRS2019

Assessment of MON-25/MMH Propellant System for Deep-Space Engines

Hypergolic propellant system of oxidizer MON-25 and fuel MMH has been considered in propulsion trade studies for NASA science mission concepts. A propulsion system using this bi-propellant combination will be capable of operating at a lower temperature as compared to traditional MON-3/MMH for heater power reduction. Operation robustness can also be realized since such a propellant system is utilized under a wide range of temperatures. Propulsion system designs and engine test programs for MON-25/MMH have been carried out since 2008. Several engine development programs have been conducted. The thrust classes of 22-Newton [5-lb(sub f)] and 445-Newton [100-lb(sub f)] were tested with the capability of a pulse mode operation for a wide range of duty cycles. Additional engine development tests are followed. Outcomes of the development efforts suggest that there is a balance of mission benefits and potential engine design and operation challenges, although the propellants can handle a low temperature. This paper will report an assessment of using the MON-25/MMH system for deep- space application.

Trinh, Huu P.↗

NASA NTRS1970

Development of a test and flight engineering oriented language, phase 3

Based on an analysis of previously developed test oriented languages and a study of test language requirements, a high order language was designed to enable test and flight engineers to checkout and operate the proposed space shuttle and other NASA vehicles and experiments. The language is called ALOFT (a language oriented to flight engineering and testing). The language is described, its terminology is compared to similar terms in other test languages, and its features and utilization are discussed. The appendix provides the specifications for ALOFT.

Kamsler, W. F.↗

NASA NTRS2000

Advanced Subsonic Technology (AST) Separate-Flow High-Bypass Ratio Nozzle Noise Reduction Program Test Report

NASA s model-scale nozzle noise tests show that it is possible to achieve a 3 EPNdB jet noise reduction with inwardfacing chevrons and flipper-tabs installed on the primary nozzle and fan nozzle chevrons. These chevrons and tabs are simple devices and are easy to be incorporated into existing short duct separate-flow nonmixed nozzle exhaust systems. However, these devices are expected to cause some small amount of thrust loss relative to the axisymmetric baseline nozzle system. Thus, it is important to have these devices further tested in a calibrated nozzle performance test facility to quantify the thrust performances of these devices. The choice of chevrons or tabs for jet noise suppression would most likely be based on the results of thrust loss performance tests to be conducted by Aero System Engineering (ASE) Inc. It is anticipated that the most promising concepts identified from this program will be validated in full scale engine tests at both Pratt & Whitney and Allied-Signal, under funding from NASA s Engine Validation of Noise Reduction Concepts (EVNRC) programs. This will bring the technology readiness level to the point where the jet noise suppression concepts could be incorporated with high confidence into either new or existing turbofan engines having short-duct, separate-flow nacelles.

Low, John K. C.↗

NASA NTRS1984

Flight testing the digital electronic engine control in the F-15 airplane

The digital electronic engine control (DEEC) is a full-authority digital engine control developed for the F100-PW-100 turbofan engine which was flight tested on an F-15 aircraft. The DEEC hardware and software throughout the F-15 flight envelope was evaluated. Real-time data reduction and data display systems were implemented. New test techniques and stronger coordination between the propulsion test engineer and pilot were developed which produced efficient use of test time, reduced pilot work load, and greatly improved quality data. The engine pressure ratio (EPR) control mode is demonstrated. It is found that the nonaugmented throttle transients and engine performance are satisfactory.

Myers, L. P.↗

NASA NTRS1928

Performance of Several Combustion Chambers Designed for Aircraft Oil Engines

Several investigations have been made on single-cylinder test engines to determine the performance characteristics of four types of combustion chambers designed for aircraft oil engines. Two of the combustion chambers studied were bulb-type precombustion chambers, the connecting orifice of one having been designed to produce high turbulence by tangential air flow in both the precombustion chamber and the cylinder. The other two were integral combustion chambers, one being dome-shaped and the other pent-roof shaped. The injection systems used included cam and eccentric driven fuel pumps, and diaphragm and spring-loaded fuel-injection valves. A diaphragm type maximum cylinder pressure indicator was used in part of these investigations with which the cylinder pressures were controlled to definite valves. The performance of the engines when equipped with each of the combustion chambers is discussed. The best performance for the tests reported was obtained with a bulb-type combustion chamber designed to give a high degree of turbulence within the bulb and cylinder. (author)

Joachim, William F↗

NASA NTRS2016

Update on the NASA Glenn Propulsion Systems Lab Ice Crystal Cloud Characterization (2015)

NASA Glenn's Propulsion Systems Lab (PSL), an altitude engine test facility, was outfitted with a spray system to generate ice crystals. The first ice crystal characterization test occurred in 2012. At PSL, turbine engines and driven rigs can experience ice crystal icing at flight altitudes, temperatures and Mach numbers. To support these tests, four ice crystal characterizations have been conducted in two different facility configurations. In addition, super-cooled liquid and mixed phase clouds have also been generated. This paper will discuss the recent learning from the previous two calibrations. It will describe some of the 12-parameter calibration space, and how those parameters interact with each other, the instrumentation used to characterize the cloud and present a sample of the cloud characterization results.

Ice Clouds↗

NASA NTRS1995

1025:1 Area Ratio Nozzle Evaluated at High Combustion Chamber Pressure

A recently completed experimental test program obtained performance data on an optimally contoured nozzle with an exit-to-throat area ratio of 1025:1 and on a truncated version of this nozzle with an area ratio of 440:1. The nozzles were tested with gaseous hydrogen and liquid oxygen propellants at combustion chamber pressures of 12.4 to 16.5 mPa (1800 to 2400 psia). Testing was conducted in the altitude test capsule at the NASA Lewis Research Center's Rocket Engine Test Facility (RETF), and results were compared with analytical performance predictions. This testing builds on previous work with this nozzle at Lewis, where testing was completed at nominal chamber pressure of 350 psia. High-area-ratio nozzles have long been sought as a means to increase the performance of spacebased rocket engines. However, as the area ratio increases, the physical size and weight of the nozzle also increase. As a result, engine and vehicle designers must make tradeoffs between nozzle size and performance enhancement. Until this test program, very little experimental data existed on the performance of the high-area-ratio nozzles used in rocket engine designs. The computer codes being used by rocket engine designers rely on data extrapolated from tests of low-area-ratio nozzles, and these extrapolations do not always provide the accuracy needed for a reliable design assessment. Therefore, we conducted this high-area-ratio nozzle testing program to provide performance data for use in rocket engine design and analysis computer codes. The nozzle had a nominal 2.54-cm- (1-in.-) diameter throat, an exit diameter of 81.3-cm (32.0-in.) at an exit-to-throat area ratio of 1025, and a length of 128.6 cm (50.6 in.). Testing was conducted in an altitude test capsule to simulate the static pressure at altitude by vacuum pumping. Data such as propellant mass flow, oxidizer-to-fuel mixture, and thrust were measured. These measurements were then used to calculate performance factors such as the thrust coefficient, the characteristic exhaust velocity efficiency, and the vacuum specific impulse. In addition, the nozzle temperature was measured to calculate the amount of heat transferred from the combustion gases to the nozzle.

Source record↗

NASA NTRS2015

Acoustic Database for Turbofan Engine Core-Noise Sources: Volume - I

In this program, a database of dynamic temperature and dynamic pressure measurements were acquired inside the core of a TECH977 turbofan engine to support investigations of indirect combustion noise. Dynamic temperature and pressure measurements were recorded for engine gas dynamics up to temperatures of 3100 degrees Fahrenheit and transient responses as high as 1000 hertz. These measurements were made at the entrance of the high pressure turbine (HPT) and at the entrance and exit of the low pressure turbine (LPT). Measurements were made at two circumferential clocking positions. In the combustor and inter-turbine duct (ITD), measurements were made at two axial locations to enable the exploration of time delays. The dynamic temperature measurements were made using dual thin-wire thermocouple probes. The dynamic pressure measurements were made using semi-infinite probes. Prior to the engine test, a series of bench, oven, and combustor rig tests were conducted to characterize the performance of the dual wire temperature probes and to define and characterize the data acquisition systems. A measurement solution for acquiring dynamic temperature and pressure data on the engine was defined. A suite of hardware modifications were designed to incorporate the dynamic temperature and pressure instrumentation into the TECH977 engine. In particular, a probe actuation system was developed to protect the delicate temperature probes during engine startup and transients in order to maximize sensor life. A set of temperature probes was procured and the TECH977 engine was assembled with the suite of new and modified hardware. The engine was tested at four steady state operating speeds, with repeats. Dynamic pressure and temperature data were acquired at each condition for at least one minute. At the two highest power settings, temperature data could not be obtained at the forward probe locations since the mean temperatures exceeded the capability of the probes. The temperature data were processed using software that accounts for the effects of convective and conductive heat transfer. The software was developed under previous NASA sponsored programs. Compensated temperature spectra and compensated time histories corresponding to the dynamic temperature of the gas stream were generated. Auto-spectral and cross-spectral analyses of the data were performed to investigate spectral features, acoustic circumferential mode content, signal coherence, and time delays. The dynamic temperature data exhibit a wideband and fairly flat spectral content. The temperature spectra do not change substantially with operating speed. The pressure spectra in the combustor and ITD exhibit generally similar shapes and amplitudes, making it difficult to identify any features that suggest the presence of indirect combustion noise. Cross-spectral analysis reveal a strong correlation between pressure and temperature fluctuations in the ITD, but little correlation between temperature fluctuations at the entrance of the HPT and pressure fluctuations downstream of it. Temperature fluctuations at the entrance of the low pressure turbine were an order of magnitude smaller than those at the entrance to the high pressure turbine. Time delay analysis of the temperature fluctuations in the combustor was inconclusive, perhaps due to the substantial mixing that occurs between the upstream and downstream locations. Time delay analysis of the temperature fluctuations in the ITD indicate that they convect at the mean flow speed. Analysis of the data did not reveal any convincing indications of the presence of indirect combustion noise. However, this analysis has been preliminary and additional exploration of the data is recommended including the use of more sophisticated signal processing to explore subtle issues that have been revealed but which are not yet fully understood or explained.

Aeroacoustics↗

NASA NTRS2017

Propulsion Controls Modeling for a Small Turbofan Engine

A nonlinear dynamic model and propulsion controller are developed for a small-scale turbofan engine. The small-scale turbofan engine is based on the Price Induction company's DGEN 380, one of the few turbofan engines targeted for the personal light jet category. Comparisons of the nonlinear dynamic turbofan engine model to actual DGEN 380 engine test data and a Price Induction simulation are provided. During engine transients, the nonlinear model typically agrees within 10 percent error, even though the nonlinear model was developed from limited available engine data. A gain scheduled proportional integral low speed shaft controller with limiter safety logic is created to replicate the baseline DGEN 380 controller. The new controller provides desired gain and phase margins and is verified to meet Federal Aviation Administration transient propulsion system requirements. In understanding benefits, there is a need to move beyond simulation for the demonstration of advanced control architectures and technologies by using real-time systems and hardware. The small-scale DGEN 380 provides a cost effective means to accomplish advanced controls testing on a relevant turbofan engine platform.

jet propulsion↗

NASA NTRS1996

Rotating Microphone Rake Measures Spinning Acoustic Modes

Rotating rake of pressure transducers developed for use in experimental studies of sources and propagation of noise generated by subsonic fan engines. Pressure transducers used as microphones to measure acoustic modes generated by, and spin with, fans. Versatility of control software used in rake-drive system enables measurements of acoustic modes on wide range of test-engine configurations. Rake-drive hardware easily adapted to different engines because not mechanically coupled to engine under test.

Konno, Kevin E.↗

NASA NTRS2000

Aerospike Engine Post-Test Diagnostic System Delivered to Rocketdyne

The NASA Glenn Research Center at Lewis Field, in cooperation with Rocketdyne, has designed, developed, and implemented an automated Post-Test Diagnostic System (PTDS) for the X-33 linear aerospike engine. The PTDS was developed to reduce analysis time and to increase the accuracy and repeatability of rocket engine ground test fire and flight data analysis. This diagnostic system provides a fast, consistent, first-pass data analysis, thereby aiding engineers who are responsible for detecting and diagnosing engine anomalies from sensor data. It uses analytical methods modeled after the analysis strategies used by engineers. Glenn delivered the first version of PTDS in September of 1998 to support testing of the engine s power pack assembly. The system was used to analyze all 17 power pack tests and assisted Rocketdyne engineers in troubleshooting both data acquisition and test article anomalies. The engine version of PTDS, which was delivered in June of 1999, will support all single-engine, dual-engine, and flight firings of the aerospike engine.

Meyer, Claudia M.↗

NASA NTRS1998

Engine Gaseous, Aerosol Precursor and Particulated Flight Altitude Conditions

The overall objective of the NASA Atmospheric Effects of Aviation Project (AEAP) is to develop scientific bases for assessing atmospheric impacts of the exhaust emissions by both current and future fleets of subsonic and supersonic aircraft. Among the six primary elements of the AEAP is Emissions Characterization. The objective of the Emission Characterization effort is to determine the exhaust emission constituents and concentrations at the engine exit plane. The specific objective of this engine test is to obtain a database of gaseous and particulate emissions as a function of fuel sulfur and engine operating conditions. The database of the particulate emission properties is to be used as a comparative baseline with subsequent flight measurement. The engine used in this test was a Pratt & Whitney F1OO-200E turbofan engine. Aviation fuel (Jet A) with a range of fuel sulfur was used. Low and high sulfur values are limited by commercially available fuels and by fuel specification limits of O.3% by weight. Test matrix was set by parametrically varying the combustor inlet temperature (T(sub 3) between idle and maximum power setting at simulated SLS and up to five other altitudes for each fuel. Four diagnostic systems, extractive and non-intrusive, were assembled for the gaseous and particulate emissions characterization measurements study. NASA extractive system includes smoke meter and analyzers for measurement of CO, CO2, NO, NOx, O2, total unburnt hydrocarbons (THC), and SO2. Particulate emissions were characterized by University of Missouri-Rolla Mobile Aerosol Sampling System. A chemical ionization mass spectrometer from the Air Force Research Laboratory at Hanscom AFB was used to measure SO2 and HNO3. Aerodyne Research. Inc. used infrared tunable diode laser absorption to measure SO2, SO3, NO, H2O and CO2.

Wey, C. C.↗