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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 757 records · Page 42

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NASA NTRS1985

Ceramics for advanced O2/H2 application

Ceramics are prime candidate materials for advanced rocket engines because they possess high-temperature capability, a tolerance for aggressive environments, and low density. A program was conducted to assess the applicability of structural ceramics to advanced versions of the Space Shuttle main engine (SSME). Operating conditions of ceramic turbine components were defined and each component in the hot-gas path was assessed in regard to materials selection, manufacturing process and feasibility, and relative structural reliability. The conclusion is that ceramic components would be viable in advanced SSME turbopumps.

Carpenter, H. W.↗

NASA NTRS1992

A demonstration of an intelligent control system for a reusable rocket engine

An Intelligent Control System for reusable rocket engines is under development at NASA Lewis Research Center. The primary objective is to extend the useful life of a reusable rocket propulsion system while minimizing between flight maintenance and maximizing engine life and performance through improved control and monitoring algorithms and additional sensing and actuation. This paper describes current progress towards proof-of-concept of an Intelligent Control System for the Space Shuttle Main Engine. A subset of identifiable and accommodatable engine failure modes is selected for preliminary demonstration. Failure models are developed retaining only first order effects and included in a simplified nonlinear simulation of the rocket engine for analysis under closed loop control. The engine level coordinator acts as an interface between the diagnostic and control systems, and translates thrust and mixture ratio commands dictated by mission requirements, and engine status (health) into engine operational strategies carried out by a multivariable control. Control reconfiguration achieves fault tolerance if the nominal (healthy engine) control cannot. Each of the aforementioned functionalities is discussed in the context of an example to illustrate the operation of the system in the context of a representative failure. A graphical user interface allows the researcher to monitor the Intelligent Control System and engine performance under various failure modes selected for demonstration.

Musgrave, Jeffrey L.↗

NASA NTRS1997

Advances in Thin Film Sensor Technologies for Engine Applications

Advanced thin film sensor techniques that can provide accurate surface strain and temperature measurements are being developed at NASA Lewis Research Center. These sensors are needed to provide minimally intrusive characterization of advanced materials (such as ceramics and composites) and structures (such as components for Space Shuttle Main Engine, High Speed Civil Transport, Advanced Subsonic Transports and General Aviation Aircraft) in hostile, high-temperature environments and for validation of design codes. This paper presents two advanced thin film sensor technologies: strain gauges and thermocouples. These sensors are sputter deposited directly onto the test articles and are only a few micrometers thick; the surface of the test article is not structurally altered and there is minimal disturbance of the gas flow over the surface. The strain gauges are palladium-13% chromium based and the thermocouples are platinum-13% rhodium vs. platinum. The fabrication techniques of these thin film sensors in a class 1000 cleanroom at the NASA Lewis Research Center are described. Their demonstration on a variety of engine materials, including superalloys, ceramics and advanced ceramic matrix composites, in several hostile, high-temperature test environments are discussed.

Lei, Jih-Fen↗

NASA NTRS1987

Numerical grid generation and flow simulation in SSME thrust chamber

The development of liquid and solid rocket engines for future space projects demands a detailed optimization process for highly efficient performance and cost reasons. Also, testing of full size engines may not be feasible when the large size requires test facilities which are cost prohibitive or if vacuum operation cannot be acquired. For such situations only scaling from small test scale measurements or accurate analytical predictions will provide the performance prior to actually flying the mission. A rigorous approach for simulating the combustion processes in liquid rocket engines by employing a direct solution of Navier-Stokes equations within the entire volume of the thrust chambers is presented. This method is illustrated in the solution of reactive flow in the Space Shuttle Main Engine (SSME) thrust chamber. The objective is to review recent improvements in the mathematical model and to present the grid generation methodology suitable for rocket thrust chamber geometries.

Gross, K. W.↗

NASA NTRS1989

Heat transfer to throat tubes in a square-chambered rocket engine at the NASA Lewis Research Center

A gaseous H2/O2 rocket engine was constructed at the NASA-Lewis to provide a high heat flux source representative of the heat flux to the blades in the high pressure fuel turbopump (HPFTP) during startup of the space shuttle main engines. The high heat flux source was required to evaluate the durability of thermal barrier coatings being investigated for use on these blades. The heat transfer, and specifically, the heat flux to tubes located at the throat of the test rocket engine was evaluated and compared to the heat flux to the blades in the HPFTP during engine startup. Gas temperatures, pressures and heat transfer coefficients in the test rocket engine were measured. Near surface metal temperatures below thin thermal barrier coatings were also measured at various angular orientations around the throat tube to indicate the angular dependence of the heat transfer coefficients. A finite difference model for a throat tube was developed and a thermal analysis was performed using the measured gas temperatures and the derived heat transfer coefficients to predict metal temperatures in the tube. Near surface metal temperatures of an uncoated throat tube were measured at the stagnation point and showed good agreement with temperatures predicted by the thermal model. The maximum heat flux to the throat tube was calculated and compared to that predicted for the leading edge of an HPFTP blade. It is shown that the heat flux to an uncooled throat tube is slightly greater than the heat flux to an HPFTP blade during engine startup.

Nesbitt, James A.↗

NASA NTRS1992

Application of powder metallurgy techniques to produce improved bearing elements for liquid rocket engines

The objective was to apply powder metallurgy techniques for the production of improved bearing elements, specifically balls and races, for advanced cryogenic turbopump bearings. The materials and fabrication techniques evaluated were judged on the basis of their ability to improve fatigue life, wear resistance, and corrosion resistance of Space Shuttle Main Engine (SSME) propellant bearings over the currently used 440C. An extensive list of candidate bearing alloys in five different categories was considered: tool/die steels, through hardened stainless steels, cobalt-base alloys, and gear steels. Testing of alloys for final consideration included hardness, rolling contact fatigue, cross cylinder wear, elevated temperature wear, room and cryogenic fracture toughness, stress corrosion cracking, and five-ball (rolling-sliding element) testing. Results of the program indicated two alloys that showed promise for improved bearing elements. These alloys were MRC-2001 and X-405. 57mm bearings were fabricated from the MRC-2001 alloy for further actual hardware rig testing by NASA-MSFC.

Moracz, D. J.↗

NASA NTRS2004

Turbomachine Sealing and Secondary Flows: Review of Sealing Performance, Customer, Engine Designer, and Research Issues - Part 1

Although forces outside our control shape our industry, turbomachine sealing research, design, and customer agendas established in 1978 by Ludwig, Campbell, and Smith in terms of specific fuel consumption and performance remain as objectives today. Advances have been made because failures of the space shuttle main engine turbomachinery ushered in a new understanding of sealing in high-power-density systems. Further, it has been shown that changes in sealing, especially for high-pressure rotors, dramatically change the performance of the entire engine or turbomachine. Maintaining seal leakages and secondary flows within engine design specifications remains the most efficient and cost effective way to enhance performance and minimize maintenance costs. This three-part review summarizes experiences, ideas, successes, and failures by NASA and the U.S. aerospace industry in secondary flow management in advanced turbomachinery. Part 1 presents system sealing, part 2 system rotordynamics, and part 3 modeling, with some overlap of each part.

Hendricks, R. C.↗

NASA NTRS1990

Effect of thermal shock on fiber-reinforced superalloy composites

An evaluation is presented of the thermal shock behavior of tungsten fiber-reinforced superalloy (FRS) composites with respect to the turbine blade requirements of rocket engine turbopumps. Each composite was reinforced unidirectionally with 40-volume-pct continuous tungsten fibers. The start-up conditions of the first-stage turbine blades of the high-pressure fuel turbopump in the Space Shuttle Main Engine (SSME) were used to investigate the thermal shock behavior of these materials. The FRS composites showed excellent thermal shock resistance, two to nine times better than the turbine blade material used in the SSME. Thermal shock cycling produced microcracks on the surfaces of the irradiated area that were less than 0.13 mm long and 0.005 mm deep. Neither fiber/matrix debonding nor microvoiding was observed.

Yuen, J. L.↗

NASA NTRS1992

Rocket engine exhaust plume diagnostics and health monitoring/management during ground testing

The current status of a rocket exhaust plume diagnostics program sponsored by NASA is reviewed. The near-term objective of the program is to enhance test operation efficiency and to provide for safe cutoff of rocket engines prior to incipient failure, thereby avoiding the destruction of the engine and the test complex and preventing delays in the national space program. NASA programs that will benefit from the nonintrusive remote sensed rocket plume diagnostics and related vehicle health management and nonintrusive measurement program are Space Shuttle Main Engine, National Launch System, National Aero-Space Plane, Space Exploration Initiative, Advanced Solid Rocket Motor, and Space Station Freedom. The role of emission spectrometry and other types of remote sensing in rocket plume diagnostics is discussed.

Chenevert, D. J.↗

NASA NTRS1982

U.S. launch systems evolution

Shuttle improvements and Shuttle-derived vehicles which could answer projected launch system demands for the 1990s are explored. Traffic volume is suggested to be at levels exceeding the STS ability to deliver, thereby necessitating use of unmanned launch vehicles. Some payload delivery increase is possible using an Aft Cargo Carrier attached to the bottom of the external tank. This configuration would handle cargo with a diameter larger than the 15 ft allowable in the Orbiter bay. Various configurations of solid rocket booster cargo rockets are described, together with use of a module containing the Shuttle main engines and avionics as a recoverable part of a system able to place cargo 30 ft in diam and 90-100 ft tall in orbit. Using liquid reusable boosters would permit an increase of cargo capacity by the Shuttle of 50%, while a side-mount cargo vehicle (unmanned) offers a payload capacity of 165-200 klb. It is predicted that launch vehicles in the beginning of the 21st century will be of a fully reusable design.

Marshall, W. R.↗

NASA NTRS1990

Multi-blocking strategies for the INS3D incompressible Navier-Stokes code

With the continuing development of bigger and faster supercomputers, computational fluid dynamics (CFD) has become a useful tool for real-world engineering design and analysis. However, the number of grid points necessary to resolve realistic flow fields numerically can easily exceed the memory capacity of available computers. In addition, geometric shapes of flow fields, such as those in the Space Shuttle Main Engine (SSME) power head, may be impossible to fill with continuous grids upon which to obtain numerical solutions to the equations of fluid motion. The solution to this dilemma is simply to decompose the computational domain into subblocks of manageable size. Computer codes that are single-block by construction can be modified to handle multiple blocks, but ad-hoc changes in the FORTRAN have to be made for each geometry treated. For engineering design and analysis, what is needed is generalization so that the blocking arrangement can be specified by the user. INS3D is a computer program for the solution of steady, incompressible flow problems. It is used frequently to solve engineering problems in the CFD Branch at Marshall Space Flight Center. INS3D uses an implicit solution algorithm and the concept of artificial compressibility to provide the necessary coupling between the pressure field and the velocity field. The development of generalized multi-block capability in INS3D is described.

Gatlin, Boyd↗

NASA NTRS1991

Artificial intelligence and expert systems in-flight software testing

The authors discuss the introduction of advanced information systems technologies such as artificial intelligence, expert systems, and advanced human-computer interfaces directly into Space Shuttle software engineering. The reconfiguration automation project (RAP) was initiated to coordinate this move towards 1990s software technology. The idea behind RAP is to automate several phases of the flight software testing procedure and to introduce AI and ES into space shuttle flight software testing. In the first phase of RAP, conventional tools to automate regression testing have already been developed or acquired. There are currently three tools in use.

Demasie, M. P.↗

NASA NTRS2005

Probabilistic Fracture Mechanics Analysis of the Orbiter's LH2 Feedline Flowliner

Work performed by Southwest Research Institute (SwRI) as part of an Independent Technical Assessment (ITA) for the NASA Engineering and Safety Center (NESC) is summarized. The ITA goal was to establish a flight rationale in light of a history of fatigue cracking due to flow induced vibrations in the feedline flowliners that supply liquid hydrogen to the space shuttle main engines. Prior deterministic analyses using worst-case assumptions predicted failure in a single flight. The current work formulated statistical models for dynamic loading and cryogenic fatigue crack growth properties, instead of using worst-case assumptions. Weight function solutions for bivariant stressing were developed to determine accurate crack "driving-forces". Monte Carlo simulations showed that low flowliner probabilities of failure (POF = 0.001 to 0.0001) are achievable, provided pre-flight inspections for cracks are performed with adequate probability of detection (POD)-specifically, 20/75 mils with 50%/99% POD. Measurements to confirm assumed POD curves are recommended. Since the computed POFs are very sensitive to the cyclic loads/stresses and the analysis of strain gage data revealed inconsistencies with the previous assumption of a single dominant vibrant mode, further work to reconcile this difference is recommended. It is possible that the unaccounted vibrational modes in the flight spectra could increase the computed POFs.

Bonacuse, Peter J.↗

NASA NTRS2010

Planning for Plume Diagnostics for Ground Testing of J-2X Engines at the SSC

John C. Stennis Space Center (SSC) is the premier test facility for liquid rocket engine development and certification for the National Aeronautics and Space Administration (NASA). Therefore, it is no surprise that the SSC will play the most prominent role in the engine development testing and certification for the J-2X engine. The Pratt & Whitney Rocketdyne J-2X engine has been selected by the Constellation Program to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage in NASA s strategy of risk mitigation for hardware development by building on the Apollo program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. Accordingly, J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development and testing efforts. In order to leverage SSC s successful and innovative expertise in the plume diagnostics for the space shuttle main engine (SSME) health monitoring,1-10 this paper will present a blueprint for plume diagnostics for various proposed ground testing activities for J-2X at SSC. Complete description of the SSC s test facilities, supporting infrastructure, and test facilities is available in Ref. 11. The A-1 Test Stand is currently being prepared for testing the J-2X engine at sea level conditions. The A-2 Test Stand is currently being used for testing the SSME and may also be used for testing the J-2X engine at sea level conditions in the future. Very recently, ground-breaking ceremony for the new A-3 rocket engine test stand took place at SSC on August 23, 2007. A-3 is the first large - scale test stand to be built at the SSC since the A and B stands were constructed in the 1960s. The A-3 Test Stand will be used for testing J-2X engines under vacuum conditions simulating high altitude operation at approximately 30,480 m (100,000 ft). To achieve the simulated altitude environment, chemical steam generators using isopropyl alcohol, LOX, and RELEASED - Printed documents may be obsolete; validate prior to use. water would run for the duration of the test and would generate approximately 2096 Kg/s of steam to reduce pressure in the test cell and downstream of the engine. The testing at the A-3 Test Stand is projected to begin in late 2010, meanwhile the J-2X component testing on A-1 is scheduled to begin later this year.

SaintCyr, William W.↗

NASA NTRS2005

Fault-Detection Tool Has Companies 'Mining' Own Business

A successful launching of NASA's Space Shuttle hinges heavily on the three Space Shuttle Main Engines (SSME) that power the orbiter. These critical components must be monitored in real time, with sensors, and compared against expected behaviors that could scrub a launch or, even worse, cause in- flight hazards. Since 1981, SSME faults have caused 23 scrubbed launches and 29 percent of total Space Shuttle downtime, according to a compilation of analysis reports. The most serious cases typically occur in the last few seconds before ignition; a launch scrub that late in the countdown usually means a period of investigation of a month or more. For example, during the launch attempt of STS-41D in 1984, an anomaly was detected in the number three engine, causing the mission to be scrubbed at T-4 seconds. This not only affected STS-41D, but forced the cancellation of another mission and caused a 2-month flight delay. In 2002, NASA s Kennedy Space Center, the Florida Institute of Technology, and Interface & Control Systems, Inc., worked together to attack this problem by creating a system that could automate the detection of mechanical failures in the SSMEs fuel control valves.

Source record↗

NASA NTRS1993

Qualitative model-based diagnostics for rocket systems

A diagnostic software package is currently being developed at NASA LeRC that utilizes qualitative model-based reasoning techniques. These techniques can provide diagnostic information about the operational condition of the modeled rocket engine system or subsystem. The diagnostic package combines a qualitative model solver with a constraint suspension algorithm. The constraint suspension algorithm directs the solver's operation to provide valuable fault isolation information about the modeled system. A qualitative model of the Space Shuttle Main Engine's oxidizer supply components was generated. A diagnostic application based on this qualitative model was constructed to process four test cases: three numerical simulations and one actual test firing. The diagnostic tool's fault isolation output compared favorably with the input fault condition.

Maul, William↗

NASA NTRS1993

Qualitative model-based diagnostics for rocket systems

Maul, William↗

NASA NTRS2004

New Screening Test Developed for the Blanching Resistance of Copper Alloys

NASA's extensive efforts towards more efficient, safer, and more affordable space transportation include the development of new thrust-cell liner materials with improved capabilities and longer lives. For rocket engines fueled with liquid hydrogen, an important metric of liner performance is resistance to blanching, a phenomenon of localized wastage by cycles of oxidation-reduction due to local imbalance in the oxygen-fuel ratio. The current liner of the Space Shuttle Main Engine combustion chamber, a Cu-3Ag-0.5Zr alloy (NARloy-Z) is degraded in service by blanching. Heretofore, evaluating a liner material for blanching resistance involved elaborate and expensive hot-fire tests performed on rocket test stands. To simplify that evaluation, researchers at the NASA Glenn Research Center developed a screening test that uses simple, in situ oxidation-reduction cycling in a thermogravimetric analyzer (TGA). The principle behind this test is that resistance to oxidation or to the reduction of oxide, or both, implies resistance to blanching. Using this test as a preliminary tool to screen alloys for blanching resistance can improve reliability and save time and money. In this test a small polished coupon is hung in a TGA furnace at the desired (service) temperature. Oxidizing and reducing gases are introduced cyclically, in programmed amounts. Cycle durations are chosen by calibration, such that all copper oxides formed by oxidation are fully reduced in the next reduction interval. The sample weight is continuously acquired by the TGA as usual.

Thomas-Ogbuji, Linus U.↗