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NASA NTRS1998

Comparison of High Aspect Ratio Cooling Channel Designs for a Rocket Combustion Chamber with Development of an Optimized Design

An analytical investigation on the effect of high aspect ratio (height/width) cooling channels, considering different coolant channel designs, on hot-gas-side wall temperature and coolant pressure drop for a liquid hydrogen cooled rocket combustion chamber, was performed. Coolant channel design elements considered were: length of combustion chamber in which high aspect ratio cooling was applied, number of coolant channels, and coolant channel shape. Seven coolant channel designs were investigated using a coupling of the Rocket Thermal Evaluation code and the Two-Dimensional Kinetics code. Initially, each coolant channel design was developed, without consideration for fabrication, to reduce the hot-gas-side wall temperature from a given conventional cooling channel baseline. These designs produced hot-gas-side wall temperature reductions up to 22 percent, with coolant pressure drop increases as low as 7.5 percent from the baseline. Fabrication constraints for milled channels were applied to the seven designs. These produced hot-gas-side wall temperature reductions of up to 20 percent, with coolant pressure drop increases as low as 2 percent. Using high aspect ratio cooling channels for the entire length of the combustion chamber had no additional benefit on hot-gas-side wall temperature over using high aspect ratio cooling channels only in the throat region, but increased coolant pressure drop 33 percent. Independent of coolant channel shape, high aspect ratio cooling was able to reduce the hot-gas-side wall temperature by at least 8 percent, with as low as a 2 percent increase in coolant pressure drop. ne design with the highest overall benefit to hot-gas-side wall temperature and minimal coolant pressure drop increase was the design which used bifurcated cooling channels and high aspect ratio cooling in the throat region. An optimized bifurcated high aspect ratio cooling channel design was developed which reduced the hot-gas-side wall temperature by 18 percent and reduced the coolant pressure drop by 4 percent. Reductions of coolant mass flow rate of up to 50 percent were possible before the hot-gas-side wall temperature reached that of the baseline. These mass flow rate reductions produced coolant pressure drops of up to 57 percent.

Wadel, Mary F.↗
NASA NTRS1961

Recombination of Hydrogen-Air Combustion Products in an Exhaust Nozzle

Thrust losses due to the inability of dissociated combustion gases to recombine in exhaust nozzles are of primary interest for evaluating the performance of hypersonic ramjets. Some results for the expansion of hydrogen-air combustion products are described. Combustion air was preheated up to 33000 R to simulate high-Mach-number flight conditions. Static-temperature measurements using the line reversal method and wall static pressures were used to indicate the state of the gas during expansion. Results indicated substantial departure from the shifting equilibrium curve beginning slightly downstream of the nozzle throat at stagnation pressures of 1.7 and 3.6 atmospheres. The results are compared with an approximate method for determining a freezing point using an overall rate equation for the oxidation of hydrogen.

Lezberg, Erwin A.↗
NASA NTRS1998

Droplet Combustion Experiment (DCE)

The first space-based experiments were performed on the combustion of free, individual liquid fuel droplets in oxidizing atmospheres. The fuel was heptane, with initial droplet diameters ranging about from 1 mm to 4 mm. The atmospheres were mixtures of helium and oxygen, at pressures of 1.00, 0.50 and 0.25 bar, with oxygen mole fractions between 20% and 40%, as well as normal Spacelab cabin air. The temperatures of the atmospheres and of the initial liquid fuel were nominally 300 K. A total of 44 droplets were burned successfully on the two flights, 8 on the shortened STS-83 mission and 36 on STS-94. The results spanned the full range of heptane droplet combustion behavior, from radiative flame extinction at larger droplet diameters in the more dilute atmospheres to diffusive extinction in the less dilute atmospheres, with the droplet disappearing prior to flame extinction at the highest oxygen concentrations. Quasisteady histories of droplet diameters were observed along with unsteady histories of flame diameters. New and detailed information was obtained on burning rates, flame characteristics and soot behavior. The results have motivated new computational and theoretical investigations of droplet combustion, improving knowledge of the chemical kinetics, fluid mechanics and heat and mass transfer processes involved in burning liquid fuels.

Haggard, John B., Jr.↗
NASA NTRS1999

NCC: A Multidisciplinary Design/Analysis Tool for Combustion Systems

A multi-disciplinary design/analysis tool for combustion systems is critical for optimizing the low-emission, high-performance combustor design process. Based on discussions between NASA Lewis Research Center and the jet engine companies, an industry-government team was formed in early 1995 to develop the National Combustion Code (NCC), which is an integrated system of computer codes for the design and analysis of combustion systems. NCC has advanced features that address the need to meet designer's requirements such as "assured accuracy", "fast turnaround", and "acceptable cost". The NCC development team is comprised of Allison Engine Company (Allison), CFD Research Corporation (CFDRC), GE Aircraft Engines (GEAE), NASA Lewis Research Center (LeRC), and Pratt & Whitney (P&W). This development team operates under the guidance of the NCC steering committee. The "unstructured mesh" capability and "parallel computing" are fundamental features of NCC from its inception. The NCC system is composed of a set of "elements" which includes grid generator, main flow solver, turbulence module, turbulence and chemistry interaction module, chemistry module, spray module, radiation heat transfer module, data visualization module, and a post-processor for evaluating engine performance parameters. Each element may have contributions from several team members. Such a multi-source multi-element system needs to be integrated in a way that facilitates inter-module data communication, flexibility in module selection, and ease of integration.

Liu, Nan-Suey↗
NASA NTRS1999

Fifth International Microgravity Combustion Workshop

On behalf of the NASA Headquarters Microgravity Research Division and the Microgravity Combustion Science Discipline Working Group, we are pleased to present these proceedings of the Fifth International Microgravity Combustion Workshop. At the time we go to press we expect to welcome to the workshop over 250 presenters and participants from U.S. academia, industry, and government; and from at least 8 international partner countries. We come together for this workshop at the beginning of the International Space Station era, where the future of microgravity combustion science programs will unfold over the next few years. As we accelerate our preparations for the ISS, this book and the growing literature base cited herein provide a summary of the accomplishments of approximately forty space-flight experiment-missions (plus nearly countless drop tests and aircraft parabolas) and a valuable resource for the new experiment ideas of the future.

Kurt R Sacksteder↗
NASA NTRS1999

Combustion of Interacting Droplet Arrays in a Microgravity Environment

Investigations into droplet interactions date back to Rex et al. Recently, Annamalai and Ryan and Annamalai published extensive reviews of droplet array and cloud combustion studies. The authors studied the change in the burning rate constant, k, (relative to that of the single droplet) that results from interactions. Under certain conditions, there exists a separation distance where the droplet lifetime reaches a minimum, or average burning rate constant is a maximum . Additionally, since inter-droplet separation distance, L, increases relative to the droplet size, D, as the burning proceeds, the burning rate is not constant throughout the burn, but changes continuously with time. Only Law and co-workers and Mikami et al. studied interactions under conditions where buoyant forces were negligible. Comparing their results with existing theory, Law and co-workers found that theory over predicted the persistency and intensity of droplet interactions. The droplet interactions also depended on the initial array configuration as well as the instantaneous array configuration. They also concluded that droplet heating was retarded due to interactions and that the burning process did not follow the "D-squared" law. Mikami et al. studied the combustion of a two-droplet array of heptane burning in air at one atm pressure in microgravity. They showed that the instantaneous burning rate constant increases throughout the droplet lifetime, even for a single droplet. Also, the burn time of the array reached a minimum at a critical inter-droplet spacing. In this article, we examine droplet interactions in normal and microgravity environments. The microgravity experiments were in the NASA GRC 2.2 and 5.2 second drop towers, and the JAMIC (Japan Microgravity Center) 10 second drop tower. Special emphasis is directed to combustion under conditions that yield finite extinction diameters, and to determine how droplet interactions affect the extinction process.

Dietrich, D. L.↗
NASA NTRS1998

Understanding Combustion Processes Through Microgravity Research

A review of research on the effects of gravity on combustion processes is presented, with an emphasis on a discussion of the ways in which reduced-gravity experiments and modeling has led to new understanding. Comparison of time scales shows that the removal of buoyancy-induced convection leads to manifestations of other transport mechanisms, notably radiative heat transfer and diffusional processes such as Lewis number effects. Examples from premixed-gas combustion, non-premixed gas-jet flames, droplet combustion, flame spread over solid and liquid fuels, and other fields are presented. Promising directions for new research are outlined, the most important of which is suggested to be radiative reabsorption effects in weakly burning flames.

Ronney, Paul D.↗
NASA NTRS1999

Experimental Study of Unsupported Nonane fuel Droplet Combustion in Microgravity

Soot formation in droplet flames is the basic component of the particulate emission process that occurs in spray combustion. The complexity of soot formation motivates a one-dimensional transport condition which has obvious advantages in modeling. Recent models of spherically symmetric droplet combustion have made this assumption when incorporating such aspects as detailed chemistry and radiation. Interestingly, spherical symmetry does not necessarily restrict the results because it has been observed that the properties of carbon formed in flames are not strongly affected by the nature of the fuel or flaming configuration. What is affected, however, are the forces acting on the soot aggregates and where they are trapped by a balance of drag and thermophoretic forces. The distribution of these forces depends on the transport conditions of the flame. Prior studies of spherical droplet flames have examined the droplet burning history of alkanes, alcohols and aromatics. Data are typically the evolution of droplet, flame, extinction, and soot shell diameters. These data are only now just beginning to find their way into comprehensive numerical models of droplet combustion to test proposed oxidation schemes for fuels such as methanol and heptane. In the present study, we report new measurements on the burning history of unsupported nonane droplets in a convection-free environment to promote spherical symmetry. The far-field gas is atmospheric pressure air at room temperature. The evolution of droplet diameter was measured using high speed cine photography of a spark-ignited, droplet within a confined volume in a drop tower. The initial droplet diameters varied between 0.5 mm and 0.6 mm. The challenge of unsupported droplets is to form, deploy and ignite them with minimal disturbance, and then to keep them in the camera field of view. Because of the difficulty of this undertaking, more sophisticated diagnostics for studying soot than photographic were not used. Supporting the test droplet by a fiber fixes the droplet position but the fiber can perturb the burning process especially for a sooting fuel. Prior studies on heptane showed little evidence for soot formation due to g-droplets of similar size the relationship between sooting and droplet diameter. For nonane droplets we expect increased sooting due to the greater number of carbon atoms. As a sooting droplet burns and its diameter decreases, proportionally less soot should form. This reduced soot, as well as the influence of soot formed earlier in the burning process which collects in a 'shell', on heat transport to the flame offers the potential for a time-varying burning rate. Such an effect was investigated and revealed in results reported here. Speculation is offered for the cause of this effect and its possible relation to soot formation.

Callahan, B. J.↗
NASA NTRS1999

Lean Premixed Combustion Stabilized by Low Swirl a Promising Concept for Practical Applications

Since its inception, the low-swirl burner (LSB) has shown to be a useful laboratory apparatus for fundamental studies of premixed turbulent flames. The LSB operates under wide ranges of equivalence ratios, flow rates, and turbulence intensities. Its flame is lifted and detached from the burner and allows easy access for laser diagnostics. The flame brush is axisymmetric and propagates normal to the incident reactants. Therefore, the LSB is well suited for investigating detailed flame structures and empirical coefficients such as flame speed, turbulence transport, and flame generated turbulence. Due to its capability to stabilize ultra-lean premixed turbulent flames (phi approx. = 0.55), the LSB has generated interest from the gas appliance industry for use as an economical low-NO(x) burner. Lean premixed combustion emits low levels of NO(x), due primarily to the low flame temperature. Therefore, it is a very effective NO(x) prevention method without involving selective catalytic reduction (SCR), fuel-air staging, or flue gas recirculation (FGR). En the gas turbine industry, substantial research efforts have already been undertaken and engines with lean premixed combustors are already in use. For commercial and residential applications, premixed pulsed combustors and premixed ceramic matrix burners are commercially available. These lean premixed combustion technologies, however, tend to be elaborate but have relatively limited operational flexibility, and higher capital, operating and maintenance costs. Consequently, these industries are continuing the development of lean premixed combustion technologies as well as exploring new concepts. This paper summarizes the research effects we have undertaken in the past few years to demonstrate the feasibility of applying the low-swirl flame stabilization method for a wide range of heating and power generation systems. The principle of flame stabilization by low-swirl is counter to the conventional high-swirl methods that rely on a recirculation zone to anchor the flame. In LSBS, flow recirculation is not promoted to allow the premixed turbulent flames to propagate freely. A LSB with an air-jet swirler is essentially an open tube with the swirler at its mid section. The small air-jets generate swirling motion only in the annular region and leaving the central core of the flow undisturbed, When this flow exits the burner tube, the angular momentum generates radial mean pressure gradient to diverge the non-swirling reactants stream. Consequently, the mean flow velocity decreases linearly. Propagating against this decelerating flow, the flame self-sustains at the position where the local flow velocity equals the flame speed, S(sub f). The LSB operates with a swirl number, S, between 0.02 to 0.1. This is much lower than the minimum S of 0.6 required for the high-swirl burners. We found that the swirl number needed for flame stabilization varies only slightly with fuel type, flow velocity, turbulent conditions and burner dimensions (i.e. throat diameter and swirl injection angle).

Cheng, R. K.↗
NASA NTRS1999

Design and Testing of a Breadboard Electrical Power Control Unit for the Fluid Combustion Facility Experiment

The Fluid Combustion Facility (FCF) Project and the Power Technology Division at the NASA Glenn Research Center (GRC) at Lewis Field in Cleveland, OH along with the Sundstrand Corporation in Rockford, IL are jointly developing an Electrical Power Converter Unit (EPCU) for the Fluid Combustion Facility to be flown on the International Space Station (ISS). The FCF facility experiment contains three racks: A core rack, a combustion rack, and a fluids rack. The EPCU will be used as the power interface to the ISS 120V(sub dc) power distribution system by each FCF experiment rack which requires 28V(sub dc). The EPCU is a modular design which contains three 120V(sub dc)-to-28V(sub dc) full-bridge, power converters rated at 1 kW(sub e) each bus transferring input relays and solid-state, current-limiting input switches, 48 current-limiting, solid-state, output switches; and control and telemetry hardware. The EPCU has all controls required to autonomously share load demand between the power feeds and--if absolutely necessary--shed loads. The EPCU, which maximizes the usage of allocated ISS power and minimizes loss of power to loads, can be paralleled with other EPCUs. This paper overviews the electrical design and operating characteristics of the EPCU and presents test data from the breadboard design.

Kimnach, Greg L.↗
NASA NTRS1999

Combustion of a Polymer (PMMA) Sphere in Microgravity

A series of low gravity, aircraft-based, experiments was conducted to investigate the combustion of supported thermoplastic polymer spheres under varying ambient conditions. The three types of thermoplastic investigated were polymethylmethacrylate (PMMA), polypropylene (PP). and polystyrene (PS). Spheres with diameters ranging from 2 mm to 6.35 mm were tested. The total initial pressure varied from 0.05 MPa to 0. 15 MPa whereas the ambient oxygen concentration varied from 19 % to 30 % (by volume). The ignition system consisted of a pair of retractable energized coils. Two CCD cameras recorded the burning histories of the spheres. The video sequences revealed a number of dynamic events including bubbling and sputtering, as well as soot shell formation and break-up during combustion of the spheres at reduced gravity. The ejection of combusting material from the burning spheres represents a fire hazard that must be considered at reduced gravity. The ejection process was found to be sensitive to polymer type. All average burning rates were measured to increase with initial sphere diameter and oxygen concentration, whereas the initial pressure had little effect. The three thermoplastic types exhibited different burning characteristics. For the same initial conditions, the burning rate of PP was slower than PMMA, whereas the burning rate of PS was comparable to PMMA. The transient diameter of the burning thermoplastic exhibited two distinct periods: an initial period (enduring approximately half of the total burn duration) when the diameter remained approximately constant, and a final period when the square of the diameter linearly decreased with time. A simple homogeneous two-phase model was developed to understand the changing diameter of the burning sphere. Its value is based on a competition between diameter reduction due to mass loss from burning and sputtering, and diameter expansion due to the processes of swelling (density decrease with heating) and bubble growth. The model relies on empirical parameters for input, such as the burning rate and the duration of the initial and final burning periods.

Yang, Jiann C.↗
NASA NTRS1999

Durability of Ceramic Matrix Composites in Combustion Environments

SiO2 scale volatility and the resulting recession of SiC has been previously identified for CVD, as well as sintered, SiC and Si3N4 materials. Linear weight loss and surface recession of SiC was observed as a result of SiO2 volatility for both fuel-lean and fuel-rich gas mixtures. A strong Arrhenius temperature dependence exist and parametric studies using multiple linear regression were used to develop recession relationships as a function of e(sup -Q/RT) central dot P(sup X)V(sup y) for both lean and rich combustion conditions. Recession of 0.2 - 2.0 micron/hr is predicted for typical combustion conditions at 1200 - 1400 C, with a somewhat higher absolute recession rate and activation energy for rich combustion versus lean.

Robinson, Raymond C.↗
NASA NTRS2000

National Combustion Code: Parallel Implementation and Performance

The National Combustion Code (NCC) is being developed by an industry-government team for the design and analysis of combustion systems. CORSAIR-CCD is the current baseline reacting flow solver for NCC. This is a parallel, unstructured grid code which uses a distributed memory, message passing model for its parallel implementation. The focus of the present effort has been to improve the performance of the NCC flow solver to meet combustor designer requirements for model accuracy and analysis turnaround time. Improving the performance of this code contributes significantly to the overall reduction in time and cost of the combustor design cycle. This paper describes the parallel implementation of the NCC flow solver and summarizes its current parallel performance on an SGI Origin 2000. Earlier parallel performance results on an IBM SP-2 are also included. The performance improvements which have enabled a turnaround of less than 15 hours for a 1.3 million element fully reacting combustion simulation are described.

Quealy, A.↗
NASA NTRS1999

Pulsating Hydrodynamic Instability and Thermal Coupling in an Extended Landau/Levich Model of Liquid-Propellant Combustion

Hydrodynamic (Landau) instability in combustion is typically associated with the onset of wrinkling of a flame surface, corresponding to the formation of steady cellular structures as the stability threshold is crossed. In the context of liquid-propellant combustion, such instability has recently been shown to occur for critical values of the pressure sensitivity of the burning rate and the disturbance wavenumber, significantly generalizing previous classical results for this problem that assumed a constant normal burning rate. Additionally, however, a pulsating form of hydrodynamic instability has been shown to occur as well, corresponding to the onset of temporal oscillations in the location of the liquid/gas interface. In the present work, we consider the realistic influence of a nonzero temperature sensitivity in the local burning rate on both types of stability thresholds. It is found that for sufficiently small values of this parameter, there exists a stable range of pressure sensitivities for steady, planar burning such that the classical cellular form of hydrodynamic instability and the more recent pulsating form of hydrodynamic instability can each occur as the corresponding stability threshold is crossed. For larger thermal sensitivities, however, the pulsating stability boundary evolves into a C-shaped curve in the disturbance-wavenumber/ pressure-sensitivity plane, indicating loss of stability to pulsating perturbations for all sufficiently large disturbance wavelengths. It is thus concluded, based on characteristic parameter values, that an equally likely form of hydrodynamic instability in liquid-propellant combustion is of a nonsteady, long-wave nature, distinct from the steady, cellular form originally predicted by Landau.

Margolis, S. B.↗
NASA NTRS2000

Thermodynamic Analysis of the Combustion of Metallic Materials

Two types of computer codes are available to assist in the thermodynamic analysis of metallic materials combustion. One type of code calculates phase equilibrium data and is represented by CALPHAD. The other type of code calculates chemical reaction by the Gordon-McBride code. The first has seen significant application for alloy-phase diagrams, but only recently has it been considered for oxidation systems. The Gordon-McBride code has been applied to the combustion of metallic materials. Both codes are limited by their treatment of non-ideal solutions and the fact they are limited to treating volatile and gaseous species as ideal. This paper examines the significance of these limitations for combustion of metallic materials. In addition, the applicability of linear-free energy relationships for solid-phase oxidation and their possible extension to liquid-phase systems is examined.

Wilson, D. Bruce↗
NASA NTRS2000

Experimental Replication of an Aeroengine Combustion Instability

Combustion instabilities in gas turbine engines are most frequently encountered during the late phases of engine development, at which point they are difficult and expensive to fix. The ability to replicate an engine-traceable combustion instability in a laboratory-scale experiment offers the opportunity to economically diagnose the problem (to determine the root cause), and to investigate solutions to the problem, such as active control. The development and validation of active combustion instability control requires that the causal dynamic processes be reproduced in experimental test facilities which can be used as a test bed for control system evaluation. This paper discusses the process through which a laboratory-scale experiment was designed to replicate an instability observed in a developmental engine. The scaling process used physically-based analyses to preserve the relevant geometric, acoustic and thermo-fluid features. The process increases the probability that results achieved in the single-nozzle experiment will be scalable to the engine.

Cohen, J. M.↗
NASA NTRS2000

Microscope-Based Fluid Physics Experiments in the Fluids and Combustion Facility on ISS

At the NASA Glenn Research Center, the Microgravity Science Program is planning to conduct a large number of experiments on the International Space Station in both the Fluid Physics and Combustion Science disciplines, and is developing flight experiment hardware for use within the International Space Station's Fluids and Combustion Facility. Four fluids physics experiments that require an optical microscope will be sequentially conducted within a subrack payload to the Fluids Integrated Rack of the Fluids and Combustion Facility called the Light Microscopy Module, which will provide the containment, changeout, and diagnostic capabilities to perform the experiments. The Light Microscopy Module is planned as a fully remotely controllable on-orbit microscope facility, allowing flexible scheduling and control of experiments within International Space Station resources. This paper will focus on the four microscope-based experiments, specifically, their objectives and the sample cell and instrument hardware to accommodate their requirements.

Doherty, Michael P.↗
NASA NTRS2000

Test Medium Effects on Ignition, Combustion and Flameholding Processes in Scramjet Combustors

The total temperatures (enthalpies) required to ground-test air-breathing (aero-propulsion) engines at high Mach number flight conditions can be achieved in a number of ways. Among these are: 1. Heat exchangers, including pre-heated ceramic beds. 2. direct electrical heating, e.g., arc discharge and resistance heaters. 3. Compression heating. 4. Shock heating, and 5. In-stream combustion, with oxygen replenishment to match air content. Each method has distinct advantages, disadvantages and limitations. All have a common characteristic of being designed for intermittent flow, due to the extreme energy required for continuous operation at simulated Mach numbers above about 3. All also distort the composition of atmospheric air to some degree, due to the high temperatures that occur in the plenum section prior to expansion of the flow to simulated flight conditions. In the case of in-stream combustion, the resulting test medium is commonly referred to as "vitiated air", being composed of oxygen, nitrogen and some fraction of combustion products.

Chinitz, W.↗