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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

CFD assessment of the pollutant environment from RD-170 propulsion system testing

Computational Fluid Dynamics (CFD) technology has been used to assess the exhaust plume pollutant environment of the RD-170 engine hot-firing on the F1 Test Stand at Marshall Space Flight Center. Researchers know that rocket engine hot-firing has the potential for forming thermal nitric oxides (NO(x)), as well as producing carbon monoxide (CO) when hydrocarbon fuels are used. Because of the complicated physics involved, however, little attempt has been made to predict the pollutant emissions from ground-based engine testing, except for simplified methods which can grossly underpredict and/or overpredict the pollutant formations in a test environment. The objective of this work, therefore, has been to develop a technology using CFD to describe the underlying pollutant emission physics from ground-based rocket engine testing. This resultant technology is based on a three-dimensional (3D), viscous flow, pressure-based CFD formulation, where wet CO and thermal NO finite-rate chemistry mechanisms are solved with a Penalty Function method. A nominal hot-firing of a RD-170 engine on the F1 stand has been computed. Pertinent test stand flow physics such as the multiple-nozzle clustered engine plume interaction, air aspiration from base and aspirator, plume mixing with entrained air that resulted in contaminant dilution and afterburning, counter-afterburning due to flame bucket water-quenching, plume impingement on the flame bucket, and restricted multiple-plume expansion and turning have been captured. The predicted total emission rates compared reasonably well with those of the existing hydrocarbon engine hot-firing test data.

Wang, Ten-See↗
NASA NTRS1990

Artificial intelligence techniques for ground test monitoring of rocket engines

An expert system is being developed which can detect anomalies in Space Shuttle Main Engine (SSME) sensor data significantly earlier than the redline algorithm currently in use. The training of such an expert system focuses on two approaches which are based on low frequency and high frequency analyses of sensor data. Both approaches are being tested on data from SSME tests and their results compared with the findings of NASA and Rocketdyne experts. Prototype implementations have detected the presence of anomalies earlier than the redline algorithms that are in use currently. It therefore appears that these approaches have the potential of detecting anomalies early eneough to shut down the engine or take other corrective action before severe damage to the engine occurs.

Ali, Moonis↗
NASA NTRS1975

Phase 2 program on ground test of refanned JT8D turbofan engines and nacelles for the 727 airplane. Volume 1: Summary

The propulsion performance, acoustic, structural, and systems changes to a 727-200 airplane retrofitted with a refan modification of the JT8D turbofan engine are evaluated. Model tests, design of certifiable airplane retrofit kit hardware, manufacture of test hardware, ground test of a current production JT8D engine, followed by test of the same engine modified to the refan configuration, detailed analyses of the retrofit impact on airplane airworthiness, performance, and noise, and a preliminary analysis of retrofit costs are included. Results indicate that the refan retrofit of the 727-200 would be certifiable and would result in a 6-to 8 EPNdb reduction in effective perceived noise level (EPNL) at the FAR 36 measuring points and an annoyance-weighted footprint area reduction of 68% to 83%. The installed refan engine is estimated to provide 14% greater takeoff thrust at zero velocity and 10% greater thrust at 100 kn (51.4 m/s). There would be an approximate 0.6% increase in cruise specific fuel consumption (SFC). The refan engine performance in conjunction with the increase in stalled weight results in a range reduction of approximately 15% over the unmodified airplane at the same brake release gross weight (BRGW), with a block fuel increase of 1.5% to 3%. With the particular model 727 that was studied, however, it is possible to operate the airplane (with minor structural modifications) at a higher BRGW and increase the range up to approximately 15% relative to the nonrefanned airplane (with equal or slightly increased noise levels). The JT8D refan engine also improves the limited-field range of the airplane.

Source record↗
NASA NTRS2016

Digital Image Correlation Techniques Applied to Large Scale Rocket Engine Testing

Rocket engine hot-fire ground testing is necessary to understand component performance, reliability and engine system interactions during development. The J-2X upper stage engine completed a series of developmental hot-fire tests that derived performance of the engine and components, validated analytical models and provided the necessary data to identify where design changes, process improvements and technology development were needed. The J-2X development engines were heavily instrumented to provide the data necessary to support these activities which enabled the team to investigate any anomalies experienced during the test program. This paper describes the development of an optical digital image correlation technique to augment the data provided by traditional strain gauges which are prone to debonding at elevated temperatures and limited to localized measurements. The feasibility of this optical measurement system was demonstrated during full scale hot-fire testing of J-2X, during which a digital image correlation system, incorporating a pair of high speed cameras to measure three-dimensional, real-time displacements and strains was installed and operated under the extreme environments present on the test stand. The camera and facility setup, pre-test calibrations, data collection, hot-fire test data collection and post-test analysis and results are presented in this paper.

Gradl, Paul R.↗
NASA NTRS2008

The General Aviation Propulsion (GAP) Program

The General Aviation Propulsion (GAP) Program Turbine Engine Element focused on the development of an advanced small turbofan engine. Goals were good fuel consumption and thrust-to-weight ratio, and very low production cost. The resulting FJX-2 turbofan engine showed the potential to meet all of these goals. The development of the engine was carried through to proof of concept testing of a complete engine system. The proof of concept engine was ground tested at sea level and in altitude test chambers. A turboprop derivative was also sea-level tested.

Source record↗
NASA NTRS2004

A Method for Calculating the Probability of Successfully Completing a Rocket Propulsion Ground Test

Propulsion ground test facilities face the daily challenges of scheduling multiple customers into limited facility space and successfully completing their propulsion test projects. Due to budgetary and schedule constraints, NASA and industry customers are pushing to test more components, for less money, in a shorter period of time. As these new rocket engine component test programs are undertaken, the lack of technology maturity in the test articles, combined with pushing the test facilities capabilities to their limits, tends to lead to an increase in facility breakdowns and unsuccessful tests. Over the last five years Stennis Space Center's propulsion test facilities have performed hundreds of tests, collected thousands of seconds of test data, and broken numerous test facility and test article parts. While various initiatives have been implemented to provide better propulsion test techniques and improve the quality, reliability, and maintainability of goods and parts used in the propulsion test facilities, unexpected failures during testing still occur quite regularly due to the harsh environment in which the propulsion test facilities operate. Previous attempts at modeling the lifecycle of a propulsion component test project have met with little success. Each of the attempts suffered form incomplete or inconsistent data on which to base the models. By focusing on the actual test phase of the tests project rather than the formulation, design or construction phases of the test project, the quality and quantity of available data increases dramatically. A logistic regression model has been developed form the data collected over the last five years, allowing the probability of successfully completing a rocket propulsion component test to be calculated. A logistic regression model is a mathematical modeling approach that can be used to describe the relationship of several independent predictor variables X(sub 1), X(sub 2),..,X(sub k) to a binary or dichotomous dependent variable Y, where Y can only be one of two possible outcomes, in this case Success or Failure. Logistic regression has primarily been used in the fields of epidemiology and biomedical research, but lends itself to many other applications. As indicated the use of logistic regression is not new, however, modeling propulsion ground test facilities using logistic regression is both a new and unique application of the statistical technique. Results from the models provide project managers with insight and confidence into the affectivity of rocket engine component ground test projects. The initial success in modeling rocket propulsion ground test projects clears the way for more complex models to be developed in this area.

Messer, Bradley P.↗
NASA NTRS2018

Acoustic Directivity of the DGEN Aero-propulsion Research Turbofan at Multiple Farfield Array Locations

The NASA Glenn Research Center's DGEN Aero-propulsion Research Turbofan (DART) is based on the Price Induction DGEN380 a small, ~500-lbf thrust class, high-bypass, geared-turbofan engine with a separate flow nozzle. The general characteristics of the DART make it an ideal candidate for utilization as a test bed for engine aeroacoustic research in a relevant performance environment. To provide a baseline acoustic profile for the DART, the system was tested in the NASA Glenn Research Center's Aero-Acoustic Propulsion Laboratory. Acoustic measurements from multiple external arrays locations were acquired over the nominal fan operating range of 50-95%. The acoustic data are evaluated and reported in terms of overall, broadband, and tonal components. The existence of interaction tones (a result of the physics of the dual-spool interactions) are noted and presented. The symmetry of the acoustic directivity was measured in preparation for potential testing in other facilities.

Turbofan Engine↗
NASA NTRS1975

Phase 2 program on ground test of refanned JT8D turbofan engines and nacelles for the 727 airplane. Volume 4: Airplane evaluation and analysis

The retrofit of JT8D-109 (refan) engines are evaluated on a 727-200 airplane in terms of airworthiness, performance, and noise. Design of certifiable hardware, manufacture, and ground testing of the essential nacelle components is included along with analysis of the certifiable airplane design to ensure airworthiness compliance and to predict the in-flight performance and noise characteristics of the modified airplane. The analyses confirm that the 727 refan airplane is certifiable. The refan airplane range would be 15% less that of the baseline airplane and block fuel would be increased by 1.5% to 3%. However, with this particular 727-200 model, with a brake release gross weight of 172,500 lb (78,245 kg), it is possible to operate the airplane (with minor structural modifications) at higher gross weights and increase the range up to 15% over the 727-200 (baseline) airplane. The refan airplane FAR Part 36 noise levels would be 6 to 8 EPNdB (effective perceived noise in decibels) below the baseline. Noise footprint studies showed that approach noise contour areas are small compared to takeoff areas. The 727 refan realizes a 68% to 83% reduction in annoyance-weighted area when compared to the 727-200 over a range of gross weights and operational procedures.

Source record↗
NASA NTRS1993

Review of NASA's Hypersonic Research Engine Project

The goals of the NASA Hypersonic Research Engine (HRE) Project, which began in 1964, were to design, develop, and construct a hypersonic research ramjet/scramjet engine for high performance and to flight-test the developed concept over the speed range from Mach 3 to 8. The project was planned to be accomplished in three phases: project definition, research engine development, and flight test using the X-15A-2 research aircraft, which was modified to carry hydrogen fuel for the research engine. The project goal of an engine flight test was eliminated when the X-15 program was canceled in 1968. Ground tests of engine models then became the focus of the project. Two axisymmetric full-scale engine models having 18-inch-diameter cowls were fabricated and tested: a structural model and a combustion/propulsion model. A brief historical review of the project with salient features, typical data results, and lessons learned is presented.

Andrews, Earl H.↗
NASA NTRS2004

Upgrades at the Propulsion Systems Lab (PSL)

The Propulsion Systems Lab (PSL) does ground testing on full size air breathing engines. These engines range from those on commercial airplanes to fighter jets. At the PSL, engineers receive test requirements from customers and put together the necessary instrumentation, data systems, power requirements, electrical control valves, and engine controls. The engineers are also responsible for facility maintenance, repairs and upgrades. There are four major sections at the PSL; the Test floor, the Data room, the Control room and, the WDPF room. On the test floor are two test cells, cell #3 and cell #4. It is within these cells that the actual engine resides for ground testing. The cells, once sealed and taken up to altitude, are capable of reaching engine inlet temperatures of 1000 F to -90 F, and various atmospheric pressures. The engine, when operational, takes in air and gives out exhaust of up to 2000 F. The exhaust is led to another section of the cell where it is cooled to 150 F before finally redirected to the appropriate disposer. Temperature and pressure transducers detect the conditions within the cell and transmit them to the data room where the results are captured, processed, analyzed, and translated to a more comprehensive language. This is made possible with the aid of several programmable logic controllers (PLCs) and instrumentation and control systems. The translated data is then sent, via the LAN, to the control room where the results can be viewed on monitors by the engineers and customers. From the control room, the test cell conditions can be changed whenever desired. During tests, a lot takes place in the facility. The WDPF control system monitors and controls all facility parameters. This summer, I will assist the engineers; on an upgrade to the facility's distributed control and dynamic data system, in preparation for an engine test that will begin in September, the installation of control systems and various miscellaneous projects around the PSL.

Audu, Abdullahi M.↗
NASA NTRS1966

Saturn V launch vehicle report.

Ground testing, development of engines, stages and ground support equipment of Saturn V launch vehicle

GROUND SUPPORT EQUIPMENT↗
NASA NTRS1993

SSME engine system integration of the alternate turbopump program

The effect of the engine level integration of the alternate High Pressure Oxidizer Turbopump (HPOTP) on the performance of the Space Shuttle Main Engine (SSME) is examined with reference to the results of the current engine system ground test data analysis. In particular, attention is given to the observed steady state and transient mainstage engine system effects with respect to various engine hardware combinations. It is concluded that none of the engine system concerns eliminate the turbomump from consideration as a permanent addition to the flight program pending certification.

Sander, E. J.↗
NASA NTRS1982

The JT9D Jet Engine Diagnostics Program

The various engine deterioration phenomena that affect JT9D performance retention were studied, and approaches to improve performance retention of engines were identified. The program included surveys of historical data, monitoring of in service engines, ground and flight testing of instrumented engines, analysis, and analytical modeling. Performance deterioration is made up of both short and long term modes, both of which are flight cycle related phenomena. Short term deterioration occurs primarily during airplane acceptance testing prior to delivery to the airline. This effect is caused by flight load and power induced clearance closures and engine deflections with resulting rubbing of airfoils and seals. Long term deterioration is caused by erosion of airfoils and gas path seals during ground operation and take off and by cyclic induced thermal distortion of the high pressure turbine airfoils. Studies of possible remedial approaches have shown that performance retention within 1 to 2 percent of initial revenue service performance can be achieved with a proper program of hot section and cold section maintenance.

Olsson, W. J.↗
NASA NTRS2016

Preliminary Results From a Heavily Instrumented Engine Ice Crystal Icing Test in a Ground Based Altitude Test Facility

Preliminary results from the heavily instrumented ALF502R-5 engine test conducted in the NASA Glenn Research Center Propulsion Systems Laboratory are discussed. The effects of ice crystal icing on a full scale engine is examined and documented. This same model engine, serial number LF01, was used during the inaugural icing test in the Propulsion Systems Laboratory facility. The uncommanded reduction of thrust (rollback) events experienced by this engine in flight were simulated in the facility. Limited instrumentation was used to detect icing on the LF01 engine. Metal temperatures on the exit guide vanes and outer shroud and the load measurement were the only indicators of ice formation. The current study features a similar engine, serial number LF11, which is instrumented to characterize the cloud entering the engine, detect/characterize ice accretion, and visualize the ice accretion in the region of interest. Data were acquired at key LF01 test points and additional points that explored: icing threshold regions, low altitude, high altitude, spinner heat effects, and the influence of varying the facility and engine parameters. For each condition of interest, data were obtained from some selected variations of ice particle median volumetric diameter, total water content, fan speed, and ambient temperature. For several cases the NASA in-house engine icing risk assessment code was used to find conditions that would lead to a rollback event. This study further helped NASA develop necessary icing diagnostic instrumentation, expand the capabilities of the Propulsion Systems Laboratory, and generate a dataset that will be used to develop and validate in-house icing prediction and risk mitigation computational tools. The ice accretion on the outer shroud region was acquired by internal video cameras. The heavily instrumented engine showed good repeatability of icing responses when compared to the key LF01 test points and during day-to-day operation. Other noticeable observations are presented.

Enigine Icing↗
NASA NTRS2016

Preliminary Results From a Heavily Instrumented Engine Ice Crystal Icing Test in a Ground Based Altitude Test Facility

Preliminary results from the heavily instrumented ALF502R-5 engine test conducted in the NASA Glenn Research Center Propulsion Systems Laboratory are discussed. The effects of ice crystal icing on a full scale engine is examined and documented. This same model engine, serial number LF01, was used during the inaugural icing test in the Propulsion Systems Laboratory facility. The uncommanded reduction of thrust (rollback) events experienced by this engine in flight were simulated in the facility. Limited instrumentation was used to detect icing on the LF01 engine. Metal temperatures on the exit guide vanes and outer shroud and the load measurement were the only indicators of ice formation. The current study features a similar engine, serial number LF11, which is instrumented to characterize the cloud entering the engine, detect/ characterize ice accretion, and visualize the ice accretion in the region of interest. Data were acquired at key LF01 test points and additional points that explored: icing threshold regions, low altitude, high altitude, spinner heat effects, and the influence of varying the facility and engine parameters. For each condition of interest, data were obtained from some selected variations of ice particle median volumetric diameter, total water content, fan speed, and ambient temperature. For several cases the NASA in-house engine icing risk assessment code was used to find conditions that would lead to a rollback event. This study further helped NASA develop necessary icing diagnostic instrumentation, expand the capabilities of the Propulsion Systems Laboratory, and generate a dataset that will be used to develop and validate in-house icing prediction and risk mitigation computational tools. The ice accretion on the outer shroud region was acquired by internal video cameras. The heavily instrumented engine showed good repeatability of icing responses when compared to the key LF01 test points and during day-to-day operation. Other noticeable observations are presented.

turbomachinery↗
NASA NTRS2016

Preliminary Results From a Heavily Instrumented Engine Ice Crystal Icing Test in a Ground Based Altitude Test Facility

Preliminary results from the Heavily Instrumented ALF503R-5 Engine test conducted in the NASA Glenn Research Center Propulsion Systems Laboratory will be discussed. The effects of ice crystal icing on a full scale engine is examined and documented. This model engine, serial number LF01, was used during the inaugural icing test in the PSL facility. The reduction of thrust (rollback) events experienced by this engine in flight were replicated in the facility. Limited instrumentation was used to detect icing. Metal temperature on the exit guide vanes and outer shroud and the load measurement were the only indicators of ice formation. The current study features a similar engine, serial number LF11, which is instrumented to characterize the cloud entering the engine, detect characterize ice accretion, and visualize the ice accretion in the region of interest.

enigine icing↗
NASA NTRS1992

SSME Automated Engine Calibration System (AECS)

An algorithm is derived for the real-time calibration of the engine fuel flowmeter and the engine mixture ratio during Space Shuttle Main Engine (SSME) ground testing. Because currently used calibration methods are post-test operations, there exists no fail-safe way of predicting at what mixture ratio a planned test will run. It is proposed that the algorithm developed here be used as part of an Automated Engine Calibration System (AECS) which could ensure that nearly all SSME tests are run at the proper mixture ratio. In this way, AECS has the potential of increasing the efficiency of the SSME ground test program. In addition to the derivation of the algorithm, an overview of this calibration system is presented along with the list of test stand facility instrumentation necessary for AECS implementation.

Greene, William D.↗
NASA NTRS2001

I(sup STAR), NASA's Next Step in Air-Breathing Propulsion for Space Access

The United States' National Aeronautics and Space Administration (NASA) has established a strategic plan for future activities in space. A primary goal of this plan is to make drastic improvements in the cost and safety of earth to low-earth-orbit transportation. One approach to achieving this goal is through the development of highly reusable, highly reliable space transportation systems analogous to the commercial airline system. In the year 2000, NASA selected the Rocket Based Combined Cycle (RBCC) engine as the next logical step towards this goal. NASA will develop a complete flight-weight, pump-fed engine system under the Integrated System Test of an Airbreathing Rocket (I(sup STAR)) Project. The objective of this project is develop a reusable engine capable of self-powering a vehicle through the air-augmented rocket, ramjet and scramjet modes required in all RBCC based operational vehicle concepts. The project is currently approved and funded to develop the engine through ground test demonstration. Plans are in place to proceed with flight demonstration pending funding approval. The project is in formulation phase and the Preliminary Requirements Review has been completed. The engine system and vehicle have been selected at the conceptual level. The I(sup STAR) engine concept is based on an air-breathing flowpath downselected from three configurations evaluated in NASA's Advanced Reusable Technology contract. The selected flowpath features rocket thrust chambers integrated into struts separating modular flowpath ducts, a variable geometry inlet, and a thermally choked throat. The engine will be approximately 220 inches long and 79 inches wide and fueled with a hydrocarbon fuel using liquid oxygen as the primary oxidizer candidate. The primary concept for the pump turbine drive is pressure-fed catalyzed hydrogen peroxide. In order to control costs, the flight demonstration vehicle will be launched from a B-52 aircraft. The vehicle concept is based on the Air Breathing Launch Vehicle 4 (ABLV4) lifting body configuration which has design heritage from NASA's NASP Program. The vehicle will be designed to accelerate from Mach 0.8 to Mach 7 and will be equipped with landing gear for horizontal landing. The complete vehicle, including the engine, will be designed for 25 flights and will be approximately 33 feet long with a total vehicle weight of approximately 25000 lbs.

Hutt, John J.↗