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NASA Lewis Propulsion Systems Laboratory Customer Guide Manual

This manual describes the Propulsion Systems Laboratory (PSL) at NASA Lewis Research Center. The PSL complex supports two large engine test cells (PSL-3 and PSL-4) that are capable of providing flight simulation to altitudes of 70,000 ft. Facility variables at the engine or test-article inlet, such as pressure, temperature, and Mach number (up to 3.0 for PSL-3 and up to 6.0 planned for PSL-4), are discussed. Support systems such as the heated and cooled combustion air systems; the altitude exhaust system; the hydraulic system; the nitrogen, oxygen, and hydrogen systems; hydrogen burners; rotating screen assemblies; the engine exhaust gas-sampling system; the infrared imaging system; and single- and multiple-axis thrust stands are addressed. Facility safety procedures are also stated.

Soeder, Ronald H.↗

Performance of Pentaborane, Pentaborane - JP-4 Fuel Mixtures, and Trimethylborate Azeotrope Fuel in a Full-scale Turbojet Engine

This report summarizes the full-scale engine tests of pentaborane, pentaborane - JP-4 fuel mixtures, and trimethylborate azeotrope fuel. The tests were conducted in a full-scale turbojet engine at a simulated altitude of 50,000 feet and Mach number of 0.08. Engine speeds were 90 to 100 percent of rated speed. Pentaborane reduced the the specific fuel consumption to two-thirds that of JP-4 fuel. However, because boron oxide collected in the engine, the performance deteriorated with continued operation of pentaborane in each of the short-duration tests reported.

Breitwiesser, Roland↗

Performance deterioration based on existing (historical) data; JT9D jet engine diagnostics program

The results of the collection and analysis of historical data pertaining to the deterioration of JT9D engine performance are presented. The results of analyses of prerepair and postrepair engine test stand performance data from a number of airlines to establish the individual as well as average losses in engine performance with respect to service use are included. Analysis of the changes in mechanical condition of parts, obtained by inspection of used gas-path parts of varying age, allowed preliminary assessments of component performance deterioration levels and identification of the causitive factors. These component performance estimates, refined by data from special engine back-to-back testing related to module performance restoration, permitted the development of preliminary models of engine component/module performance deterioration with respect to usage. The preliminary assessment of the causes of module performance deterioration and the trends with usage are explained, along with the role each module plays in overall engine performance deterioration. Preliminary recommendations with respect to operating and maintenance practices which could be adopted to control the level of performance deterioration are presented. The needs for additional component sensitivity testing as well as outstanding issues are discussed.

Sallee, G. P.↗

Special projects of the geographic applications program

Alternative uses were investigated for the Mississippi Test Facility since the phaseout of Saturn 5 engine testing. Using the facility for collecting remotely sensed data is suggested for regional studies. The capabilities of various remote sensing devices to detect, identify, monitor, or determine effects of environmental pollution are summarized. Which pollutants could be monitored from spacecraft, high and low altitude aircraft, and ground based platforms are determined. Examples of special processing and enhancement and analysis techniques used in connection with remote sensing data are provided.

North, G. W.↗

Multi-Fuel Rotary Engine for General Aviation Aircraft

Design studies, conducted for NASA, of Advanced Multi-fuel General Aviation and Commuter Aircraft Rotary Stratified Charge Engines are summarized. Conceptual design studies of an advanced engine sized to provide 186/250 shaft KW/HP under cruise conditions at 7620/25,000 m/ft. altitude were performed. Relevant engine development background covering both prior and recent engine test results of the direct injected unthrottled rotary engine technology, including the capability to interchangeably operate on gasoline, diesel fuel, kerosene, or aviation jet fuel, are presented and related to growth predictions. Aircraft studies, using these resultant growth engines, define anticipated system effects of the performance and power density improvements for both single engine and twin engine airplanes. The calculated results indicate superior system performance and 30 to 35% fuel economy improvement for the Rotary-engine airplanes as compared to equivalent airframe concept designs with current baseline engines. The research and technology activities required to attain the projected engine performance levels are also discussed.

Jones, C.↗

A knowledge-based system design/information tool for aircraft flight control systems

Research aircraft have become increasingly dependent on advanced electronic control systems to accomplish program goals. These aircraft are integrating multiple disciplines to improve performance and satisfy research objective. This integration is being accomplished through electronic control systems. Systems design methods and information management have become essential to program success. The primary objective of the system design/information tool for aircraft flight control is to help transfer flight control system design knowledge to the flight test community. By providing all of the design information and covering multiple disciplines in a structured, graphical manner, flight control systems can more easily be understood by the test engineers. This will provide the engineers with the information needed to thoroughly ground test the system and thereby reduce the likelihood of serious design errors surfacing in flight. The secondary object is to apply structured design techniques to all of the design domains. By using the techniques in the top level system design down through the detailed hardware and software designs, it is hoped that fewer design anomalies will result. The flight test experiences are reviewed of three highly complex, integrated aircraft programs: the X-29 forward swept wing; the advanced fighter technology integration (AFTI) F-16; and the highly maneuverable aircraft technology (HiMAT) program. Significant operating technologies, and the design errors which cause them, is examined to help identify what functions a system design/informatin tool should provide to assist designers in avoiding errors.

Mackall, Dale A.↗

Multidisciplinary propulsion simulation using the numerical propulsion system simulator (NPSS)

Implementing new technology in aerospace propulsion systems is becoming prohibitively expensive. One of the major contributions to the high cost is the need to perform many large scale system tests. The traditional design analysis procedure decomposes the engine into isolated components and focuses attention on each single physical discipline (e.g., fluid for structural dynamics). Consequently, the interactions that naturally occur between components and disciplines can be masked by the limited interactions that occur between individuals or teams doing the design and must be uncovered during expensive engine testing. This overview will discuss a cooperative effort of NASA, industry, and universities to integrate disciplines, components, and high performance computing into a Numerical propulsion System Simulator (NPSS).

Claus, Russel W.↗

Antenna-assembling mechanism test on ETS-7

The Communications Research Laboratory plans to test an antenna-assembling mechanism on the Engineering Test Satellite 7. The test is one of the application missions for the space robotics experiments that will be conducted mainly by the National Space Development Agency of Japan (NASDA). The purpose of the test is to verify the ability of the antenna assembling mechanism to function in space and to experiment on the teleoperation of a space robot to develop antenna-assembling technology. We present the test experiment plans and the outline of the onboard assembling mechanism.

Suzuki, Yoshiaki↗

Validation of High Aspect Ratio Cooling in a 89 kN (20,000 lb(sub f)) Thrust Combustion Chamber

In order to validate the benefits of high aspect ratio cooling channels in a large scale rocket combustion chamber, a high pressure, 89 kN (20,000 lbf) thrust, contoured combustion chamber was tested in the NASA Lewis Research Center Rocket Engine Test Facility. The combustion chamber was tested at chamber pressures from 5.5 to 11.0 MPa (800-1600 psia). The propellants were gaseous hydrogen and liquid oxygen at a nominal mixture ratio of six, and liquid hydrogen was used as the coolant. The combustion chamber was extensively instrumented with 30 backside skin thermocouples, 9 coolant channel rib thermocouples, and 10 coolant channel pressure taps. A total of 29 thermal cycles, each with one second of steady state combustion, were completed on the chamber. For 25 thermal cycles, the coolant mass flow rate was equal to the fuel mass flow rate. During the remaining four thermal cycles, the coolant mass flow rate was progressively reduced by 5, 6, 11, and 20 percent. Computer analysis agreed with coolant channel rib thermocouples within an average of 9 percent and with coolant channel pressure drops within an average of 20 percent. Hot-gas-side wall temperatures of the chamber showed up to 25 percent reduction, in the throat region, over that of a conventionally cooled combustion chamber. Reducing coolant mass flow yielded a reduction of up to 27 percent of the coolant pressure drop from that of a full flow case, while still maintaining up to a 13 percent reduction in a hot-gas-side wall temperature from that of a conventionally cooled combustion chamber.

Wadel, Mary F.↗

Ares Launch Vehicles Overview: Space Access Society

America is returning to the Moon in preparation for the first human footprint on Mars, guided by the U.S. Vision for Space Exploration. This presentation will discuss NASA's mission, the reasons for returning to the Moon and going to Mars, and how NASA will accomplish that mission in ways that promote leadership in space and economic expansion on the new frontier. The primary goals of the Vision for Space Exploration are to finish the International Space Station, retire the Space Shuttle, and build the new spacecraft needed to return people to the Moon and go to Mars. The Vision commits NASA and the nation to an agenda of exploration that also includes robotic exploration and technology development, while building on lessons learned over 50 years of hard-won experience. NASA is building on common hardware, shared knowledge, and unique experience derived from the Apollo Saturn, Space Shuttle, and contemporary commercial launch vehicle programs. The journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, which transports the Orion Crew Exploration Vehicle, and the Ares V Cargo Launch Vehicle, which transports the Lunar Surface Access Module. The architecture for the lunar missions will use one launch to ferry the crew into orbit, where it will rendezvous with the Lunar Module in the Earth Departure Stage, which will then propel the combination into lunar orbit. The imperative to explore space with the combination of astronauts and robots will be the impetus for inventions such as solar power and water and waste recycling. This next chapter in NASA's history promises to write the next chapter in American history, as well. It will require this nation to provide the talent to develop tools, machines, materials, processes, technologies, and capabilities that can benefit nearly all aspects of life on Earth. Roles and responsibilities are shared between a nationwide Government and industry team. The Exploration Launch Projects Office at the Marshall Space Flight Center manages the design, development, testing, and evaluation of both vehicles and serves as lead systems integrator. A little over a year after it was chartered, the Exploration Launch Projects team is testing engine components, refining vehicle designs, performing wind tunnel tests, and building hardware for the first flight test of Ares I-X, scheduled for spring 2009. The Exploration Launch Projects team conducted the Ares I System Requirements Review (SRR) at the end of 2006. In Ares' first year, extensive trade studies and evaluations were conducted to refine the design initially recommended by the Exploration Systems Architecture Study, conceptual designs were analyzed for fitness, and the contractual framework was assembled to enable a development effort unparalleled in American space flight since the Space Shuttle. Now, the project turns its focus to the Preliminary Design Review (PDR), scheduled for 2008. Taking into consideration the findings of the SRR, the design of the Ares I is being tightened and refined to meet the safety, operability, reliability, and affordability goals outlined by the Constellation Program. The Ares V is in the early design stage, focusing its activities on requirements validation and ways to develop this heavy-lift system so that synergistic hardware commonality between it and the Ares I can reduce the operational footprint and foster sustained exploration across the decades ahead.

Cook, Steve↗

Human Space Exploration: The Moon, Mars, and Beyond

America is returning to the Moon in preparation for the first human footprint on Mars, guided by the U.S. Vision for Space Exploration. This presentation will discuss NASA's mission, the reasons for returning to the Moon and going to Mars, and how NASA will accomplish that mission in ways that promote leadership in space and economic expansion on the new frontier. The primary goals of the Vision for Space Exploration are to finish the International Space Station, retire the Space Shuttle, and build the new spacecraft needed, to return people to the Moon and go to Mars. The Vision commits NASA and the nation to an agenda of exploration that also includes robotic exploration and technology development, while building on lessons learned over 50 years of hard-won experience. Why the Moon? Many questions about the Moon's potential resources and how its history is linked to that of Earth were spurred by the brief Apollo explorations of the 1960s and 1970s. This new venture will carry more explorers to more diverse landing sites with more capable tools and equipment for extended expeditions. The Moon also will serve as a training ground before embarking on the longer, more difficult trip to Mars. NASA plans to build a lunar outpost at one of the lunar poles, learn to live off the land, and reduce dePendence on Earth for longer missions. America needs to extend its ability to survive in hostile environments close to our home planet before astronauts will reach Mars, a planet very much like Earth. NASA has worked with scientists to define lunar exploration goals and is addressing the opportunities for a range of scientific study on Mars. In order to reach the Moon and Mars within a lifetime and within budget, NASA is building on common hardware, shared knowledge, and unique experience derived from the Apollo Saturn, Space Shuttle and contemporary commercial launch vehicle programs. The journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, which transports the Orion Crew Exploration Vehicle, and the Ares V Cargo Launch Vehicle, which transports the Lunar Surface Access Module. The architecture for the lunar missions will use one launch to ferry the crew into orbit, where it will rendezvous with the Lunar Module in the Earth Departure Stage, which will then propel the combination into lunar orbit. The imperative to explore space with the combination of astronauts and robots will be the impetus for inventions such as solar power and water and waste recycling. This next chapter in NASA's history promises to write the next chapter in American history, as well. It will require this nation to provide the talent to develop tools, machines, materials, processes, technologies, and capabilities that can benefit nearly all aspects of life on Earth. Roles and responsibilities are shared between a nationwide Government and industry team. The Exploration Launch Projects Office at the Marshall Space Flight Center manages the design, development, testing, and evaluation of both vehicles and serves as lead systems integrator. A little over a year after it was chartered, the Exploration Launch Projects team is testing engine components, refining vehicle designs, performing wind tunnel tests, and building hardware for the first flight test of Ares I-l, scheduled for spring 2009. The U.S. Vision for Space Exploration lays out a roadmap for a long-term venture of discovery. This endeavor will inspire and attract the best and brightest students to power this nation successfully to the Moon, Mars, and beyond. If one equates the value proposition for space with simple dollars and cents, the potential of the new space economy is tremendous, from orbital space delivery services for the International Space Station to mining and solar energy collection on the Moon and asteroids. The Vision for Space Exploration is fundamentally about bringing the resources of the solar system within the economic sphere of humaind. Given the immense size of our solar system, the amount of available material and energy within it present an enormous economic opportunity.

Sexton, Jeffrey D.↗

Pratt & Whitney/Boeing Engine Validation of Noise Reduction Concepts Final Report for NASA Contract NAS3-97144, Phase 2

This report presents results of the work completed in Phase 2 of the Engine Validation of Noise Reduction Concepts (EVNRC) contract. The purpose of the program is to validate, through engine testing, advanced noise reduction concepts aimed at reducing engine noise up to 6 EPNdB and improving nacelle suppression by 50 percent relative to 1992 technology. Phase 1 of the program is completed and is summarized in NASA/CR-2014-218088.

Bock, Larry A.↗

Full scale technology demonstration of a modern counterrotating unducted fan engine concept: Component test

The UDF trademark (Unducted Fan) engine is a new aircraft engine concept based on an ungeared, counterrotating, unducted, ultra-high-bypass turbofan configuration. This engine is being developed to provide a high thrust-to-weight ratio powerplant with exceptional fuel efficiency for subsonic aircraft application. This report covers the testing of pertinent components of this engine such as the fan blades, control and actuation system, turbine blades and spools, seals, and mixer frame.

Source record↗

Wind-tunnel Tests of a 2-engine Airplane Model as a Preliminary Study of Flight Conditions Arising on the Failure of the Engine

Wind tunnel tests of a 15-foot-span model of a two-engine low wing transport airplane were made as a preliminary study of the emergency arising from the failure of one engine in flight. Two methods of reducing the initial yawing moment resulting from the failure of one engine were investigated and the equilibrium conditions were explored for two basic modes on one engine, one with zero angle of sideslip and the other with several degrees of sideslip. The added drag resulting from the unsymmetrical attitudes required for flight on one engine was determined for the model airplane. The effects of the application of power upon the stability, controllability, lift, and drag of the model airplane were measured. A dynamic pressure survey of the propeller slipstream was made in the neighborhood of the tail surfaces at three angles of attack. The added parasite drag of the model airplane resulting from the unfavorable conditions of flight on one engine was estimated. From 35 to 50 percent of this added drag was due to the drag of the dead engine propeller and the other 50 to 65 percent was due to the unsymmetrical attitude of the airplane. The mode of flight on one engine in which the angle of sideslip was zero was found to require less power than the mode in which the angle of sideslip was several degrees.

Hartman, Edwin P↗

NASA Plum Brook Station In-Space Propulsion Facility Test Stand Characterization Hot Fire Test

A test facility modification to enable small scale altitude propulsion testing at the NASA Glenn Research Center's In-Space Propulsion (ISP) Facility was verified with a hot fire test campaign. As the facility's primary steam supply system undergoes refurbishment, the alternate facility configuration, known as the "vacuum accumulator" mode, would enable rocket engine testing up to 10,000 lbf thrust. The NASA Johnson Space Center developed the vehicle for the verification test campaign: the Integrated Cryogenic Propulsion Test Article (ICPTA). Constructed primarily from assets of the former Morpheus Project, the ICPTA provided an integrated liquid oxygen (LOX) / liquid methane (LCH4) propulsion system including a 2,800 lbf thrust main engine. The ISP Facility's vacuum accumulator configuration leveraged the large test volume of the facility and a diffuser insert to maintain altitude conditions. During hot fire, the ICPTA main engine "started" the diffuser insert constructed for the test campaign. As a result, the test chamber upstream of the diffuser insert remained at altitude conditions throughout the hot fire. Upon engine shut down, a backflow deflector mitigated blow back into the test chamber by restricting the mass flow and redirecting it away from the test article. The test campaign successfully characterized the performance of the vacuum accumulator configuration. In addition, it provided an opportunity to collect data for an integrated LOX / LCH4 propulsion system in an altitude and thermal vacuum environment.

Rocket Engine Testing↗

A Preliminary Study of Fuel Injection and Compression Ignition as Applied to an Aircraft Engine Cylinder

This report summarizes some results obtained with a single cylinder test engine at the Langley Field Laboratory during a preliminary investigation of the problem of applying fuel injection and compression ignition to aircraft engines. For this work a standard Liberty Engine cylinder was fitted with a high compression, 11.4 : 1 compression ratio, piston, and equipped with an airless injection system, including a primary fuel pump, an injection pump, and an automatic injection valve. The results obtained during this investigation have indicated the possibility of applying airless injection and compression ignition to a cylinder of this size, 8-inch bore by 7-inch stroke, when operating at engine speeds as high as 1,850 R. P. M. A minimum specific fuel consumption with diesel engine fuel oil of 0.30 pound per I. HP. Hour was obtained when developing about 16 B. HP. At 1,730 R. P. M.

Gardiner, Arthur W↗

Flight Investigation of the Cooling Characteristics of a Two-row Radial Engine Installation III : Engine Temperature Distribution

The temperature distribution of a two-row radial engine in a twin-engine airplane has been investigated in a series of flight tests. The test engine was operated over a wide range of conditions at density altitudes of 5000 and 20,000 feet; quantitative results are presented showing the effects of flight and engine variables upon average engine temperature and over-all temperature spread. Discussions of the effect of the variables on the shape of the temperature patterns and on the temperature distribution of individual cylinders are also included. The results indicate that, for the tests conducted, the temperature distribution patterns were chiefly determined by the fuel-air ratio and cooling-air distributions. It was possible to calculate individual cylinder temperature, on the assumption of equal power distribution among cylinders, to within an average of plus or minus 14 degrees F. of the actual temperature. A considerable change occurred in either the spread or the thrust axis, the average engine fuel-air ratio, the engine speed, the power, or the blower ratio. Smaller effects on the temperature pattern were noticed with a change in cowl-flap opening and altitude. In most of the tests, a change in conditions affected the temperature of the barrels less than that of the heads. The variation of flight and engine variables had a negligible effect on the temperature distributions of the individual cylinders. (author)

Rennak, Robert M↗