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NASA NTRS1989

Assessment, development, and application of combustor aerothermal models

The gas turbine combustion system design and development effort is an engineering exercise to obtain an acceptable solution to the conflicting design trade-offs between: combustion efficiency, gaseous emissions, smoke, ignition, restart, lean blowout, burner exit temperature quality, structural durability, and life cycle cost. For many years, these combustor design trade-offs have been carried out with the help of fundamental reasoning and extensive component and bench testing, backed by empirical and experience correlations. Recent advances in the capability of computational fluid dynamics (CFD) codes have led to their application to complex three-dimensional flows such as those in the gas turbine combustor. A number of U.S. Govern- ment and industry sponsored programs have made significant contributions to the formulation, development, and verification of an analytical combustor design methodology which will better define the aerothermal loads in a combustor, and be a valuable tool for design of future combustion systems. The contributions made by NASA Hot Section Technology (HOST) sponsored Aero- thermal Modeling and supporting programs are described in this paper

J D Holdeman↗

NASA NTRS1990

Aerothermal environment induced by mismatch at the SSME main combustion chamber-nozzle joint

The computational study reported here is motivated by a Space Shuttle main engine hardware problem detected in post-flight and post-test inspections. Of interest are the potential for hot gas ingestion into the joint (G15) at the main combustion chamber-to-nozzle interface and the effect of particular goemetric nonuniformities on that gas ingestion. The flowfield in the G15 region involves supersonic flow past a rounded forward facing step preceded by a deep narrow cavity. This paper describes the physical problem associated with joint G15 and computational investigations of the G15 aerothermal environment. The associated flowfield was simulated in two and three space dimensions using the United Solutions Algorithm (USA) computational fluid dynamics code series. A benchmark calculation of experimentally measured supersonic flow over of a square cavity was performed to demonstrate the accuracy of the USA code in analyzing flows similar to the G15 computational flowfield. The G15 results demonstrate the mechanism for hot gas ingestion into the joint and reveal the sensitivity to salient geometric nonuniformities.

Mcconnaughey, H. V.↗

NASA NTRS1991

Adaptive finite element analysis of hypersonic laminar flows for aerothermal load predictions

The use of an adaptive mesh refinement procedure for analyzing hypersonic laminar flows with application to aerothermal load predictions is described. The adaptation procedure, which uses both quadrilateral and triangular elements, is implemented with the multistep Galerkin-Runge-Kutta scheme. Elements that lie in regions of strong gradients are refined based on indicators to obtain better definition of flow features. The effectiveness of the adaptive procedure is demonstrated by modeling Mach 11.7 flow over a 15-deg ramp. Numerical results are compared with predictions of strong interaction theories and experimental data. Surface quantities such as heating rates and pressure loads, critical for the effective design of high-speed vehicles, are found to be in good agreement with experimental values.

Ramakrishnan, R.↗

NASA NTRS1992

A database of aerothermal measurements in hypersonic flow for CFD validation

This paper presents an experimental database selected and compiled from aerothermal measurements obtained on basic model configurations on which fundamental flow phenomena could be most easily examined. The experimental studies were conducted in hypersonic flows in 48-inch, 96-inch, and 6-foot shock tunnels. A special computer program was constructed to provide easy access to the measurements in the database as well as the means to plot the measurements and compare them with imported data. The database contains tabulations of model configurations, freestream conditions, and measurements of heat transfer, pressure, and skin friction for each of the studies selected for inclusion. The first segment contains measurements in laminar flow emphasizing shock-wave boundary-layer interaction. In the second segment, measurements in transitional flows over flat plates and cones are given. The third segment comprises measurements in regions of shock-wave/turbulent-boundary-layer interactions. Studies of the effects of surface roughness of nosetips and conical afterbodies are presented in the fourth segment of the database. Detailed measurements in regions of shock/shock boundary layer interaction are contained in the fifth segment. Measurements in regions of wall jet and transpiration cooling are presented in the final two segments.

Holden, M. S.↗

NASA NTRS1997

Aerothermal Performance Constraints for Hypervelocity Small Radius Unswept Leading Edges and Nosetips

Small radius leading edges and nosetips were utilized to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating would cause severe ablation or blunting of the available thermal protection system materials. Recent studies indicate that ultrahigh temperature ceramic (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp UHTC leading edge components in the near future. Aerothermal performance constraints for sharp components made from these materials are presented in this work to demonstrate the effects of convective blocking, surface catalycity, surface emissivity, and rarefied flow effects on steady state operation at altitudes from sea level to 90 km. These components are capable of steady state operation at velocities up to 7.9 km/s at attitudes near 90 km.

Kolodziej, Paul↗

NASA NTRS1997

Aerothermal Performance Constraints for Small Radius Leading Edges Operating at Hypervelocity

Small radius leading edges and nosetips were used to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating blunted the available thermal protection system materials. Recent studies indicate that ultra-high temperature composite (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp leading edge components in the near future. Steady-state aerothermal performance constraints for UHTC components are presented in this paper to identify their non-ablating operational capability at altitudes from sea level to 90 km. An integrated design tool was developed to estimate these constraints. The tool couples aerothermodynamic heating with material response using commercial finite element analysis software and is capable of both steady-state and transient analysis. Performance during entry is analyzed by transient thermal analysis along the trajectory. The thermal load condition from the transient thermal analysis is used to estimate thermal stress. Applying the tool to UHTC materials shows that steady-state, non-ablating operation of a HfB2/SiC(A-7) (A-7) component is possible at velocities approaching Earth's circular orbital velocity of 7.9 km/s at altitudes approaching 70 km.

Kolodziej, Paul↗

NASA NTRS1997

Spacecraft Orbital Debris Reentry: Aerothermal Analysis

In the past 40 years, thousands of objects have been placed in Earth orbit and are being tracked. Space hardware reentry survivability must be evaluated to assess risks to human life and property on the ground. The objective of this paper is to present results of a study to determine altitude of demise (burn-up) or survivability of reentering objects. Two NASA/JSC computer codes - Object Reentry Survival Analysis Tool (ORSAT) and Miniature ORSAT (MORSAT) were used to determine trajectories, aerodynamic aerothermal environment, and thermal response of selected spacecraft components. The methodology of the two codes is presented, along with results of a parametric study of reentering objects modeled as spheres and cylinders. Parameters varied included mass, diameter, wall thickness, ballistic coefficient, length, type of material, and mode of tumbling/spinning. Two fragments of a spent Delta second stage undergoing orbital decay, stainless steel cylindrical propellant tank and titanium pressurization sphere, were evaluated with ORSAT and found to survive entry, as did the actual objects. Also, orbital decay reentry predictions of the Japanese Advanced Earth Observing Satellite (ADEOS) aluminum and nickel box-type components and the Russian COSMOS 954 satellite beryllium cylinders were made with MORSAT. These objects were also shown to survive reentry.

Rochelle, Wm. C.↗

NASA NTRS1998

Engineering Aerothermal Analysis for X-34 Thermal Protection System Design

Design of the thermal protection system for any hypersonic flight vehicle requires determination of both the peak temperatures over the surface and the heating-rate history along the flight profile. In this paper, the process used to generate the aerothermal environments required for the X-34 Testbed Technology Demonstrator thermal protection system design is described as it has evolved from a relatively simplistic approach based on engineering methods applied to critical areas to one of detailed analyses over the entire vehicle. A brief description of the trajectory development leading to the selection of the thermal protection system design trajectory is included. Comparisons of engineering heating predictions with wind-tunnel test data and with results obtained using a Navier- Stokes flowfield code and an inviscid/boundary layer method are shown. Good agreement is demonstrated among all these methods for both the ground-test condition and the peak heating flight condition. Finally, the detailed analysis using engineering methods to interpolate the surface-heating-rate results from the inviscid/boundary layer method to predict the required thermal environments is described and results presented.

Wurster, Kathryn E.↗

NASA NTRS1998

Engineering Aerothermal Analysis for X-34 Thermal Protection System Design

Design of the thermal protection system for any hypersonic flight vehicle requires determination of both the peak temperatures over the surface and the heating-rate history along the flight profile. In this paper, the process used to generate the aerothermal environments required for the X-34 Testbed Technology Demonstrator thermal protection system design is described as it has evolved from a relatively simplistic approach based on engineering methods applied to critical areas to one of detailed analyses over the entire vehicle. A brief description of the trajectory development leading to the selection of the thermal protection system design trajectory is included. Comparisons of engineering heating predictions with wind-tunnel test data and with results obtained using a Navier-Stokes flowfield code and an inviscid/boundary layer method are shown. Good agreement is demonstrated among all these methods for both the ground-test condition and the peak heating flight condition. Finally, the detailed analysis using engineering methods to interpolate the surface-heating-rate results from the inviscid/boundary layer method to predict the required thermal environments is described and results presented.

Wurster, Kathryn E.↗

NASA NTRS2000

Thermoelastic Analysis of Hyper-X Camera Windows Suddenly Exposed to Mach 7 Stagnation Aerothermal Shock

To visually record the initial free flight event of the Hyper-X research flight vehicle immediately after separation from the Pegasus(registered) booster rocket, a video camera was mounted on the bulkhead of the adapter through which Hyper-X rides on Pegasus. The video camera was shielded by a protecting camera window made of heat-resistant quartz material. When Hyper-X separates from Pegasus, this camera window will be suddenly exposed to Mach 7 stagnation thermal shock and dynamic pressure loading (aerothermal loading). To examine the structural integrity, thermoelastic analysis was performed, and the stress distributions in the camera windows were calculated. The critical stress point where the tensile stress reaches a maximum value for each camera window was identified, and the maximum tensile stress level at that critical point was found to be considerably lower than the tensile failure stress of the camera window material.

Ko, William L.↗

NASA NTRS1995

Aerothermal Performance Envelopes for Hypersonic Small Radius Unswept Leading Edges and Nosetips

Small radius leading edges and nosetips were utilized to minimize wave drag in early hypersonic vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating would cause severe ablation or blunting of the available thermal protection system materials. Recent studies indicate that diboride composite materials are shape stable under extreme aerothermodynamic heating at ultra high temperatures. Aerothermal performance envelopes for sharp components made from these materials are presented in this work to demonstrate the effects of convective blocking, surface catalycity, surface emissivity, and rarefied flow effects on steady state operation at altitudes from sea level to 90 km. These components are capable of steady state operation at velocities up to 7.9 km/s at altitudes near 90 km.

Kolodziej, Paul↗

NASA NTRS1997

Analysis of Mars Pathfinder Entry Data, Aerothermal Heating, and Heat Shield Material Response

The Mars Pathfinder heatshield contained several thermocouples and resistance thermometers. A description of the experiment, the entry data, and analysis of the entry environment and material response is presented. In particular, the analysis addresses uncertainties of the data and the fluid dynamics and material response models. The calculations use the latest trajectory and atmosphere reconstructions for the Pathfinder entry. A modified version of the GIANTS code is used for CFD (computational fluid dynamics) analyses, and FIAT is used for material response. The material response and flowfield are coupled appropriately. Three different material response models are considered. The analysis of Pathfinder entry data for validation of aerothermal heating and material response models is complicated by model uncertainties and unanticipated data-acquisition and processing problems. We will discuss these issues as well as ramifications of the data and analysis for future Mars missions.

Milos, Frank↗

NASA NTRS1997

Grid Generation Issues and CFD Simulation Accuracy for the X33 Aerothermal Simulations

Grid generation issues relating to the simulation of the X33 aerothermal environment using the GASP code are explored. Required grid densities and normal grid stretching are discussed with regards to predicting the fluid dynamic and heating environments with the desired accuracy. The generation of volume grids is explored and includes discussions of structured grid generation packages such as GRIDGEN, GRIDPRO and HYPGEN. Volume grid manipulation techniques for obtaining desired outer boundary and grid clustering using the OUTBOUND code are examined. The generation of the surface grid with the required surface grid with the required surface grid topology is also discussed. Utilizing grids without singular axes is explored as a method of avoiding numerical difficulties at the singular line.

Polsky, Susan↗

NASA NTRS2002

Statistical Methods for Rapid Aerothermal Analysis and Design Technology

The cost and safety goals for NASA's next generation of reusable launch vehicle (RLV) will require that rapid high-fidelity aerothermodynamic design tools be used early in the design cycle. To meet these requirements, it is desirable to establish statistical models that quantify and improve the accuracy, extend the applicability, and enable combined analyses using existing prediction tools. The research work was focused on establishing the suitable mathematical/statistical models for these purposes. It is anticipated that the resulting models can be incorporated into a software tool to provide rapid, variable-fidelity, aerothermal environments to predict heating along an arbitrary trajectory. This work will support development of an integrated design tool to perform automated thermal protection system (TPS) sizing and material selection.

Morgan, Carolyn↗

NASA NTRS2004

Aerothermal Performance Constraint Analysis of Sharp Nosecaps and Leading Edges

The main objective of this work is to predict the Aerothermal Performance Constraint (APC) for a class of Crew Transfer Vehicles (CTV) with shap noses and wing leading edges made out of UHTC which is a family of Ultra High Temperature Ceramics materials developed at NASA Ames. The APC is based on the theoretical temperature limit of the material which is usually encountered at the CTV nose or wing leading edge. The APC places a lower limit on the trajectory of the CTV in the altitude velocity space. The APC is used as one of the constraints in developing reentry and abort trajectories for the CTV. The trajectories are then used to generate transient thermal response of the nosecaps and wing leading edges which are represented as either a one piece of UHTC or two piece (UHTC + RCC) with perfect axial contact. The final paper will include more details about the analysis procedure and will also include results for reentry and abort design trajectories.

Rizk, Yehia↗

NASA NTRS1998

Aerothermal Heating Predictions for Mars Microprobe

A combination of computational predictions and experimental measurements of the aerothermal heating expected on the two Mars Microprobes during their entry to Mars are presented. The maximum, non-ablating, heating rate at the vehicle's stagnation point (at alpha = 0 degrees) is predicted for an undershoot trajectory to be 194 Watts per square centimeters with associated stagnation point pressure of 0.064 atm. Maximum stagnation point pressure occurs later during the undershoot trajectory and is 0.094 atm. From computations at seven overshoot-trajectory points, the maximum heat load expected at the stagnation point is near 8800 Joules per square centimeter. Heat rates and heat loads on the vehicle's afterbody are much lower than the forebody. At zero degree angle-of-attack, heating over much of the hemi-spherical afterbody is predicted to be less than 2 percent of the stagnation point value. Good qualitative agreement is demonstrated for forebody and afterbody heating between CFD calculations at Mars entry conditions and experimental thermographic phosphor measurements from the Langley 20-Inch Mach 6 Air Tunnel. A novel approach which incorporates six degree-of-freedom trajectory simulations to perform a statistical estimate of the effect of angle-of-attack, and other off-nominal conditions, on heating is included.

Mitcheltree, R. A.↗

NASA NTRS2010

Methodology for the Assessment of 3D Conduction Effects in an Aerothermal Wind Tunnel Test

This slide presentation reviews a method for the assessment of three-dimensional conduction effects during test in a Aerothermal Wind Tunnel. The test objectives were to duplicate and extend tests that were performed during the 1960's on thermal conduction on proturberance on a flat plate. Slides review the 1D versus 3D conduction data reduction error, the analysis process, CFD-based analysis, loose coupling method that simulates a wind tunnel test run, verification of the CFD solution, Grid convergence, Mach number trend, size trends, and a Sumary of the CFD conduction analysis. Other slides show comparisons to pretest CFD at Mach 1.5 and 2.16 and the geometries of the models and grids.

Oliver, Anthony Brandon↗

NASA NTRS2010

Development of a Tool to Recreate the Mars Science Laboratory Aerothermal Environment

The Mars Science Laboratory will enter the Martian atmosphere in 2012 with multiple char depth sensors and in-depth thermocouples in its heatshield. The aerothermal environment experienced by MSL may be computationally recreated using the data from the sensors and a material response program, such as the Fully Implicit Ablation and Thermal (FIAT) response program, through the matching of the char depth and thermocouple predictions of the material response program to the sensor data. A tool, CHanging Inputs from the Environment of FIAT (CHIEF), was developed to iteratively change different environmental conditions such that FIAT predictions match within certain criteria applied to an external data set. The computational environment is changed by iterating on the enthalpy, pressure, or heat transfer coefficient at certain times in the trajectory. CHIEF was initially compared against arc-jet test data from the development of the MSL heatshield and then against simulated sensor data derived from design trajectories for MSL. CHIEF was able to match char depth and in-depth thermocouple temperatures within the bounds placed upon it for these cases. Further refinement of CHIEF to compare multiple time points and assign convergence criteria may improve accuracy.

Beerman, A. F.↗