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At least 667 records · Page 37

Advanced thrust chamber technology for in-space propulsion system

Two new concepts, the afterburning technique and the spray optimization method for the purpose of upgrading the combustion efficiency and C efficiency, are examined to assess the technical merits and hurdles that need to be resolved. Details of combustion and aerodynamic processes of monomethylhydrazine and nitrogen tetroxides in a toroidal shaped combustion chamber of a variable thrust engine, devised with a wall impingement cooling system and the secondary injection of an oxidizer from the chamber wall for an afterburning, are investigated for the selected secondary injection conditions. With an appropriate injection condition, the combustion efficiency was found to be almost 23 percent higher than that of an engine without afterburning.

Chiu, H. H.↗

Three-Dimensional Measurements of Fuel Distribution in High-Pressure, High- Temperature, Next-Generation Aviation Gas Turbine Combustors

In our world-class, optically accessible combustion facility at the NASA Lewis Research Center, we have developed the unique capability of making three-dimensional fuel distribution measurements of aviation gas turbine fuel injectors at actual operating conditions. These measurements are made in situ at the actual operating temperatures and pressures using the JP-grade fuels of candidate next-generation advanced aircraft engines for the High Speed Research (HSR) and Advanced Subsonics Technology (AST) programs. The inlet temperature and pressure ranges used thus far are 300 to 1100 F and 80 to 250 psia. With these data, we can obtain the injector spray angles, the fuel mass distributions of liquid and vapor, the degree of fuel vaporization, and the degree to which fuel has been consumed. The data have been used to diagnose the performance of injectors designed both in-house and by major U.S. engine manufacturers and to design new fuel injectors with overall engine performance goals of increased efficiency and reduced environmental impact. Mie scattering is used to visualize the liquid fuel, and laser-induced fluorescence is used to visualize both liquid and fuel vapor.

Hicks, Yolanda R.↗

High-Pressure Combustion Testing Reveals Promise of Low-Emission Combustors for Advanced Subsonic Gas Turbines

NASA Lewis Research Center's new, world-class, 60-atm combustor research facility, the Advanced Subsonic Combustion Rig (ASCR), is in operation and producing highly unique research data. At operating pressures to 800 psia, emissions of nitrogen oxides were reduced by greater than 70 percent with an advanced fuel injector designed at NASA Lewis. Data, including exhaust emissions and pressure and temperature distributions, were acquired at high pressures and temperatures representative of future subsonic engines. Results to date represent an improved understanding of the formation of nitrogen oxides at these high pressures (twice the pressure of previous combustor tests) and temperatures.

Lyons, Valerie J.↗

Propulsion System Choices and Their Implications

In defining a space vehicle architecture, the propulsion system and related subsystem choices will have a major influence on achieving the goals and objectives desired. There are many alternatives and the choices made must produce a system that meets the performance requirements, but at the same time also provide the greatest opportunity of reaching all of the required objectives. Recognizing the above, the SPST Functional Requirements subteam has drawn on the knowledge, expertise, and experience of its members, to develop insight that wiIJ effectively aid the architectural concept developer in making the appropriate choices consistent with the architecture goals. This data not only identifies many selected choices, but also, more importantly, presents the collective assessment of this subteam on the "pros" and the "cons" of these choices. The propulsion system choices with their pros and cons are presented in five major groups. A. System Integration Approach. Focused on the requirement for safety, reliability, dependability, maintainability, and low cost. B. Non-Chemical Propulsion. Focused on choice of propulsion type. C. Chemical Propulsion. Focused on propellant choice implications. D. Functional Integration. Focused on the degree of integration of the many propulsive and closely associated functions, and on the choice of the engine combustion power cycle. E. Thermal Management. Focused on propellant tank insulation and integration. Each of these groups is further broken down into subgroups, and at that level the consensus pros and cons are presented. The intended use of this paper is to provide a resource of focused material for architectural concept developers to use in designing new advanced systems including college design classes. It is also a possible source of input material for developing a model for designing and analyzing advanced concepts to help identify focused technology needs and their priorities.

Joyner, Claude R., II↗

Regeneratively Cooled Liquid Oxygen/Methane Technology Development

The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LOX)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon exploration studies. The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. NASA-Marshall Space Flight Center (MSFC) in concert with industry partner Pratt & Whitney Rocketdyne (PWR) utilized a Space Act Agreement to test an oxygen/methane engine system in the Summer of 2010. PWR provided a 5,500 lbf (24,465 N) LOX/LCH4 regenerative cycle engine to demonstrate advanced thrust chamber assembly hardware and to evaluate the performance characteristics of the system. The chamber designs offered alternatives to traditional regenerative engine designs with improvements in cost and/or performance. MSFC provided the test stand, consumables and test personnel. The hot fire testing explored the effective cooling of one of the thrust chamber designs along with determining the combustion efficiency with variations of pressure and mixture ratio. The paper will summarize the status of these efforts.

Robinson, Joel W.↗

Regeneratively Cooled Liquid Oxygen/Methane Technology Development Between NASA MSFC and PWR

The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LOX)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon exploration studies. The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. NASA-Marshall Space Flight Center (MSFC) in concert with industry partner Pratt & Whitney Rocketdyne (PWR) utilized a Space Act Agreement to test an oxygen/methane engine system in the Summer of 2010. PWR provided a 5,500 lbf (24,465 N) LOX/LCH4 regenerative cycle engine to demonstrate advanced thrust chamber assembly hardware and to evaluate the performance characteristics of the system. The chamber designs offered alternatives to traditional regenerative engine designs with improvements in cost and/or performance. MSFC provided the test stand, consumables and test personnel. The hot fire testing explored the effective cooling of one of the thrust chamber designs along with determining the combustion efficiency with variations of pressure and mixture ratio. The paper will summarize the status of these efforts.

Robinson, Joel W.↗

Determination of Combustion Product Radicals in a Hydrocarbon Fueled Rocket Exhaust Plume

The identification of metallic effluent materials in a rocket engine exhaust plume indicates the health of the engine. Since 1989, emission spectroscopy of the plume of the Space Shuttle Main Engine (SSME) has been used for ground testing at NASA's Stennis Space Center (SSC). This technique allows the identification and quantification of alloys from the metallic elements observed in the plume. With the prospect of hydrocarbon-fueled rocket engines, such as Rocket Propellant 1 (RP-1) or methane (CH4) fueled engines being considered for use in future space flight systems, the contributions of intermediate or final combustion products resulting from the hydrocarbon fuels are of great interest. The effect of several diatomic molecular radicals, such as Carbon Dioxide , Carbon Monoxide, Molecular Carbon, Methylene Radical, Cyanide or Cyano Radical, and Nitric Oxide, needs to be identified and the effects of their band systems on the spectral region from 300 nm to 850 nm determined. Hydrocarbon-fueled rocket engines will play a prominent role in future space exploration programs. Although hydrogen fuel provides for higher engine performance, hydrocarbon fuels are denser, safer to handle, and less costly. For hydrocarbon-fueled engines using RP-1 or CH4 , the plume is different from a hydrogen fueled engine due to the presence of several other species, such as CO2, C2, CO, CH, CN, and NO, in the exhaust plume, in addition to the standard H2O and OH. These species occur as intermediate or final combustion products or as a result of mixing of the hot plume with the atmosphere. Exhaust plume emission spectroscopy has emerged as a comprehensive non-intrusive sensing technology which can be applied to a wide variety of engine performance conditions with a high degree of sensitivity and specificity. Stennis Space Center researchers have been in the forefront of advancing experimental techniques and developing theoretical approaches in order to bring this technology to a more mature stage.

Langford, Lester A.↗

NASA Tech Briefs, Februrary 2013

Topics covered include: Measurements of Ultra-Stable Oscillator (USO) Allan Deviations in Space; Gaseous Nitrogen Orifice Mass Flow Calculator; Validation of Proposed Metrics for Two-Body Abrasion Scratch Test Analysis Standards; Rover Low Gain Antenna Qualification for Deep Space Thermal Environments; Automated, Ultra-Sterile Solid Sample Handling and Analysis on a Chip; Measuring and Estimating Normalized Contrast in Infrared Flash Thermography; Spectrally and Radiometrically Stable, Wideband, Onboard Calibration Source; High-Reliability Waveguide Vacuum/Pressure Window; Methods of Fabricating Scintillators With Radioisotopes for Beta Battery Applications; Magnetic Shield for Adiabatic Demagnetization Refrigerators (ADR); CMOS-Compatible SOI MESFETS for Radiation-Hardened DC-to-DC Converters; Silicon Heat Pipe Array; Adaptive Phase Delay Generator; High-Temperature, Lightweight, Self-Healing Ceramic Composites for Aircraft Engine Applications; Treatment to Control Adhesion of Silicone-Based Elastomers; High-Temperature Adhesives for Thermally Stable Aero-Assist Technologies; Rockballer Sample Acquisition Tool; Rock Gripper for Sampling, Mobility, Anchoring, and Manipulation; Advanced Magnetic Materials Methods and Numerical Models for Fluidization in Microgravity and Hypogravity; Data Transfer for Multiple Sensor Networks Over a Broad Temperature Range; Using Combustion Synthesis to Reinforce Berms and Other Regolith Structures; Visible-Infrared Hyperspectral Image Projector; Three-Axis Attitude Estimation With a High-Bandwidth Angular Rate Sensor Change_Detection.m; AGATE: Adversarial Game Analysis for Tactical Evaluation; Ionospheric Simulation System for Satellite Observations and Global Assimilative; Modeling Experiments (ISOGAME); An Extensible, User- Modifiable Framework for Planning Activities; Mission Operations Center (MOC) - Precipitation Processing System (PPS) Interface Software System (MPISS); Automated 3D Damaged Cavity Model Builder for Lower Surface Acreage Tile on Orbiter; Mixed Linear/Square-Root Encoded Single-Slope Ramp Provides Low-Noise ADC with High Linearity for Focal Plane Arrays; RUSHMAPS: Real-Time Uploadable Spherical Harmonic Moment Analysis for Particle Spectrometers; Powered Descent Guidance with General Thrust-Pointing Constraints; X-Ray Detection and Processing Models for Spacecraft Navigation and Timing; and Extreme Ionizing-Radiation-Resistant Bacterium

Source record↗

Advanced cooling techniques for high-pressure, hydrocarbon-fueled rocket engines

The regenerative cooling limits (maximum chamber pressure) are defined for oxygen/hydrocarbon (Methane, Propane, and RP-1) rocket engines over a thrust range of 20,000 to 600,000 lbf for a reusable life of 250 missions. Chamber pressure limits are first defined without a hot-gas wall carbon layer (unenhanced designs). Cooling enhancement chamber pressure limits are then established for seven thermal barriers (carbon layer, ceramic coating, graphite liner, film cooling, zoned combustion, transpiration cooling, and a combination of two of the above). The maximum regenerative-cooled chamber pressure is attained with the oxygen/methane propellant combination.

Cook, R. T.↗

Creep Testing of High-Temperature Cu-8 Cr-4 Nb Alloy Completed

A Cu-8 at.% Cr-4 at.% Nb (Cu-8 Cr-4 Nb) alloy is under development for high-temperature, high heatflux applications, such as actively cooled, hypersonic vehicle heat exchangers and rocket engine combustion chambers. Cu-8 Cr-4 Nb offers a superior combination of strength and conductivity. It has also shown exceptional low-cycle fatigue properties. Following preliminary testing to determine the best processing route, a more detailed testing program was initiated to determine the creep lives and creep rates of Cu-8 Cr-4 Nb alloy specimens produced by extrusion. Testing was conducted at the NASA Lewis Research Center with constant-load vacuum creep units. Considering expected operating temperatures and mission lives, we developed a test matrix to accurately determine the creep properties of Cu-8 Cr-4 Nb between 500 and 800 C. Six bars of Cu-8 Cr-4 Nb were extruded. From these bars, 54 creep samples were machined and tested. The figure on the left shows the steady-state, or second-stage, creep rates for the samples. Comparison data for NARloy-Z (Cu-3 wt % Ag-0.5 wt % Zr), the alloy currently used in combustion chamber liners, were not unavailable. Therefore the steady-state creep rates for Cu at similar temperatures are presented. As expected, in comparison to pure Cu, the creep rates for Cu-8 Cr-4 Nb are much lower. The lives of the samples are presented in the figure on the right. As shown, Cu-8 Cr-4 Nb at 800 C is comparable to NARloy-Z at 648 C. At equivalent temperatures, Cu-8 Cr-4 Nb enjoys a 20 to 50 percent advantage in stress for a given life and 1 to 3 orders of magnitude greater life at a given stress. The improved properties allow for design tradeoffs and improvements in new and existing heat exchangers such as the next generation of combustion chamber liners. Average creep rates for Cu-8 Cr-4 Nb and pure Cu are shown. Average creep lives for Cu-8 Cr- 4 Nb and NARloy-Z are also shown. Currently, two companies are interested in the commercial usage of the Cu-8 Cr-4 Nb alloy. The Rocketdyne Division of Rockwell International is conducting independent testing to analyze the properties for their projected needs in advanced rocket engine applications. Metallamics, a company based in Traverse City, Michigan, is entering into a Space Act Agreement to evaluate and test Cu-Cr-Nb alloys as materials for welding electrodes that are used in robotic welding operations. Creep rate is one of the alloy properties that determines the degree to which a welding electrode will mushroom or expand at the tip. A material with a low creep rate will resist mushrooming and give the electrode a longer life, minimizing downtime. This application holds the potential for large-scale usage of the alloy in the automotive and other industries. Success here would dramatically decrease the cost of the alloy and increase availability for aerospace applications.

Source record↗

Development of Advanced In-Cylinder Components and Tribological Systems for Low Heat Rejection Diesel Engines

In-cylinder components and tribological system concepts were designed, fabricated and tested at conditions anticipated for a 55% thermal efficiency heavy duty diesel engine for the year 2000 and beyond. A Cummins L10 single cylinder research engine was used to evaluate a spherical joint piston and connecting rod with 19.3 MPa (2800 psi) peak cylinder pressure capability, a thermal fatigue resistant insulated cylinder head, radial combustion seal cylinder liners, a highly compliant steel top compression ring, a variable geometry turbocharger, and a microwave heated particulate trap. Components successfully demonstrated in the final test included spherical joint connecting rod with a fiber reinforced piston, high conformability steel top rings with wear resistant coatings, ceramic exhaust ports with strategic oil cooling and radial combustion seal cylinder liner with cooling jacket transfer fins. A Cummins 6B diesel was used to develop the analytical methods, materials, manufacturing technology and engine components for lighter weight diesel engines without sacrificing performance or durability. A 6B diesel engine was built and tested to calibrate analytical models for the aluminum cylinder head and aluminum block.

Yonushonis, T. M.↗

Advancing Transportation Efficiency and Electric Vehicles in Tonga: A Review of Relevant Trends and Best Practices

Tonga is facing a transportation sector characterized by private passenger vehicles, poorly maintained roads and walkways, and an inadequate public transit system. By understanding detailed global and regional trends for transport energy efficiency and electric vehicles (EVs) within this context, the Government of Tonga can proactively plan its future transportation systems. In addition to global and regional trends, this report also covers a variety of international case studies and examines Tonga's own transportation policies and actions through this lens. Jurisdictions leading in EV adoption have implemented policies such as reducing taxes on EVs compared to internal combustion engine (ICE) vehicles, providing subsidies and rebates for EV charger installation, instituting an age limit on imported ICE vehicles, and developing EV maintenance courses to expand the skill set of current automotive technicians. Although there are key challenges and barriers to widespread EV adoption in Tonga, multiple studies have researched potential political, technical, financial, and educational interventions that can be adapted and applied in Tonga. Therefore, the purpose of this report is to synthesize the relevant trends and best practices in order to provide Tonga's Ministry of Meteorology, Energy, Information, Disaster Management, Environment, Climate Change and Communication (MEIDECC) with a wide range of information on electric vehicles (EVs) and transportation efficiency.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Active Suppression of Instabilities in Engine Combustors

A method of feedback control has been proposed as a means of suppressing thermo-acoustic instabilities in a liquid- fueled combustor of a type used in an aircraft engine. The basic principle of the method is one of (1) sensing combustor pressure oscillations associated with instabilities and (2) modulating the rate of flow of fuel to the combustor with a control phase that is chosen adaptively so that the pressure oscillations caused by the modulation oppose the sensed pressure oscillations. The need for this method arises because of the planned introduction of advanced, lean-burning aircraft gas turbine engines, which promise to operate with higher efficiencies and to emit smaller quantities of nitrogen oxides, relative to those of present aircraft engines. Unfortunately, the advanced engines are more susceptible to thermoacoustic instabilities. These instabilities are hard to control because they include large dead-time phase shifts, wide-band noise characterized by amplitudes that are large relative to those of the instabilities, exponential growth of the instabilities, random net phase walks, and amplitude fluctuations. In this method (see figure), the output of a combustion-pressure sensor would be wide-band-pass filtered and then further processed to generate a control signal that would be applied to a fast-actuation valve to modulate the flow of fuel. Initially, the controller would rapidly take large phase steps in order to home in, within a fraction of a second, to a favorable phase region within which the instability would be reduced. Then the controller would restrict itself to operate within this phase region and would further restrict itself to operate within a region of stability, as long as the power in the instability signal was decreasing. In the phase-shifting scheme of this method, the phase of the control vector would be made to continuously bounce back and forth from one boundary of an effective stability region to the other. Computationally, this scheme would be implemented by the adaptive sliding phaser averaged control (ASPAC) algorithm, which requires very little detailed knowledge of the combustor dynamics. In the ASPAC algorithm, the power of the instability signal would be calculated from the wide-bandpass- filtered combustion-pressure signal and averaged over a period of time (typically of the order of a few hundredths of a second) corresponding to the controller updating cycle [not to be confused with the controller sampling cycle, which would be much shorter (typically of the order of 10(exp -4) second)].

Kopasakis, George↗

Effects of a CFD-improved dimple stepped-lip piston on thermal efficiency and emissions in a medium-duty diesel engine

Diesel piston-bowl shape is a key design parameter that affects spray-wall interactions and turbulent flow development, and in turn affects the engine’s thermal efficiency and emissions. It is hypothesized that thermal efficiency can be improved by enhancing squish-region vortices as they are hypothesized to promote fuel-air mixing, leading to faster heat-release rates. However, the strength and longevity of these vortices decrease with advanced injection timings for typical stepped-lip (SL) piston geometries. Dimple stepped-lip (DSL) pistons enhance vortex formation at early injection timings. Previous engine experiments with such a bowl show 1.4% thermal efficiency gains over an SL piston. However, soot was increased dramatically [SAE 2022-01-0400]. In a previous study, a new DSL bowl was designed using non-combusting computational fluid dynamic simulations. This improved DSL bowl is predicted to promote stronger, more rotationally energetic vortices than the baseline DSL piston: it employs shallower, narrower, and steeper-curved dimples that are placed further out into the squish region. In the current experimental study, this improved bowl is tested in a medium-duty diesel engine and compared against the SL piston over an injection timing sweep at low-load and part-load operating conditions. No substantial thermal efficiency gains are achieved at the early injection timing with the improved DSL design, but soot emissions are lowered by 45% relative to the production SL piston, likely due to improved air utilization and soot oxidation. However, these benefits are lost at late injection timings, where the DSL piston renders a lower thermal efficiency than that of the SL piston. Energy balance analyses show higher wall heat transfer with the DSL piston than with the SL piston despite a 1.3% reduction in the piston surface area. Vortex enhancement may not necessarily lead to improved efficiency as more energetic squish-region vortices can lead to higher convective heat transfer losses.

42 ENGINEERING↗

Detailed fuel spray analysis techniques

Fuel spray analyses which are a necessary input to the analytical modeling of the complex mixing and combustion processes which occur in advanced combustor systems are discussed. It is anticipated that by controlling fuel air reaction conditions, combustor temperatures can be better controlled, leading to improved combustion system durability. The capability to measure liquid droplet size, velocity, and number density throughout a fuel spray and to utilize this measurement technique in laboratory benchmark experiments was demonstrated. The experiment to characterize fuel sprays is described. The experiments and data are useful for application to and validation of turbulent flow modeling to improve the design systems of future advanced technology engines.

Mularz, E. J.↗

A hydrogen-oxygen rocket engine coolant passage design program (RECOP) for fluid-cooled thrust chambers and nozzles

The design of coolant passages in regeneratively cooled thrust chambers is critical to the operation and safety of a rocket engine system. Designing a coolant passage is a complex thermal and hydraulic problem requiring an accurate understanding of the heat transfer between the combustion gas and the coolant. Every major rocket engine company has invested in the development of thrust chamber computer design and analysis tools; two examples are Rocketdyne's REGEN code and Aerojet's ELES program. In an effort to augment current design capabilities for government and industry, the NASA Lewis Research Center is developing a computer model to design coolant passages for advanced regeneratively cooled thrust chambers. The RECOP code incorporates state-of-the-art correlations, numerical techniques and design methods, certainly minimum requirements for generating optimum designs of future space chemical engines. A preliminary version of the RECOP model was recently completed and code validation work is in progress. This paper introduces major features of RECOP and compares the analysis to design points for the first test case engine; the Pratt & Whitney RL10A-3-3A thrust chamber.

Tomsik, Thomas M.↗

Effect Of Gravity On Porous Tricalcium Phosphate And Nonstoichiometric Titanium Carbide Produced Via Combustion Synthesis

Novel processing techniques, such as self-propagating high temperature synthesis (SHS), have the capability to rapidly produce advanced porous materials that are difficult to fabricate by other methods. This processing technique is also capable of near net shape synthesis, while variable gravity allows the manipulation of the structure and composition of the material. The creation of porous tricalcium phosphate (TCP) is advantageous in the biomaterials field, since it is both a biocompatible material and an osteoconductive material. Porous tricalcium phosphate produced via SHS is an excellent candidate for bone scaffold material in the bone regeneration process. The porosity allows for great vascularization and ingrowth of tissue. Titanium Carbide is a nonstoichiometric biocompatible material that can be incorporated into a TiC-Ti composite system using combustion synthesis. The TiC-Ti composite exhibits a wide range of mechanical and chemical properties. Both of these material systems (TCP and TiC-Ti) can be used to advantage in designing novel bone replacement materials. Gravity plays an important role in both the pore structure and the chemical uniformity of these composite systems and offers considerable potential in advanced bone engineering.

Castillo, M.↗

Development and Evaluation of a Novel Fuel Injector Design Method using Hybrid-Additive Manufacturing (Final Report)

The widespread application of metal additive manufacturing (AM) technologies has enabled exploration of complex design spaces to achieve optimally performing components. Current optimization techniques make use of several advanced methods to provide designs that are superior to existing versions. However, they seldom discuss the manufacturability of the optimal designs. The objective of this project was to develop a design optimization tool that simultaneously optimizes fuel injector hardware and the combustor flow field with optimization functions and constraints that consider both combustor performance and manufacturability using advanced AM methods and post-processing. In this way, the resultant hardware design is inherently imbued with our most advanced knowledge of combustion physics and AM methods from its conception.

36 MATERIALS SCIENCE↗