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Sliding friction coefficients and wear rates of promising piston seal materials were measured under temperature, environmental, velocity, and loading conditions that are representative of the low heat rejection (LHR) diesel engine environment. These materials included carbides, oxides, and nitrides. In addition, silicon nitride and partially stablized zirconia disks (cylinder liners) were ion-implanted with TiNi, Ni, Co, and Cr, and subsequently run against carbide pins (piston rings), with the objective of producing reduced friction via solid lubrication at elevated temperature. Friction and wear measurements were obtained using pin-on-disk laboratory experiments and a unique engine friction test rig. Unmodified ceramic sliding couples were characterized at all temperatures by friction coefficients of 0.24 and above during the pin-on-disk tests. The coefficient at 800 C in an oxidizing environment was reduced to below 0.1, for certain material combination, by the ion-implantation of TiNi or Co. This beneficial effect was found to derive from the lubricious Ti, Ni, and Co oxides. Similar results were demonstrated on the engine friction test rig at lower temperatures. The structural integrity and feasibility of engine application with the most promising material combination were demonstrated during a 30-hour single-cylinder, direct-injection diesel engine test.
Ignition-chamber engines and their fuel injection systems are investigated.
The installation procedure, maintenance, adjustment and operation of a Lucas type fuel injection system for 13B rotary racing engine is outlined. Components of the fuel injection system and installation procedure and notes are described. Maintenance, adjustment, and operation are discussed.
A three-dimensional computer code, KIVA, is being modified to include state-of-the-art submodels for diesel engine flow and combustion. Improved and/or new submodels which have already been implemented and previously reported are: wall heat transfer with unsteadiness and compressibility, laminar-turbulent characteristic time combustion with unburned HC and Zeldo'vich NO(x), and spray/wall impingement with rebounding and sliding drops. Progress on the implementation of improved spray drop drag and drop breakup models, the formulation and testing of a multistep kinetics ignition model, and preliminary soot modeling results are described. In addition, the use of a block structured version of KIVA to model the intake flow process is described. A grid generation scheme was developed for modeling realistic (complex) engine geometries, and computations were made of intake flow in the ports and combustion chamber of a two-intake-value engine. The research also involves the use of the code to assess the effects of subprocesses on diesel engine performance. The accuracy of the predictions is being tested by comparisons with engine experiments. To date, comparisons were made with measured engine cylinder pressure, temperature and heat flux data, and the model results are in good agreement with the experiments. Work is in progress that will allow validation of in-cylinder flow and soot formation predictions. An engine test facility is described that is being used to provide the needed validation data. Test results were obtained showing the effect of injection rate and split injections on engine performance and emissions.
Fuel was injected from different type of injection nozzles into the combustion chamber of the NACA combustion apparatus, operated as a compression-ignition engine. High speed motion pictures were taken of the fuel sprays and combustion. Single-orifice nozzles of 0.008, 0.020, and 0.040 inch diameter, and multiorifice nozzles having 2, 6, and 16 orifices were tested. Nozzles having impinging jets and slit orifices were also included. The photographs indicate that the rate of vapor diffusion from the spray is comparatively slow and that this slow rate of diffusion for combustion chambers with little or no air flow prevents the compression-ignition engine from giving the high performance inherent in the high compression ratios. The sprays from the multiorifice nozzles destroyed the air movement to a greater extent than did those from single orifice nozzles. It is concluded that high performance cannot be realized until the methods of distributing the fuel are improved by means of the injection-nozzle design, air flow, or both.
Design studies of advanced multifuel general aviation and commuter aircraft rotary stratified charge engines are summarized. Conceptual design studies were performed at two levels of technology, on advanced general aviation engines sized to provide 186/250 shaft kW/hp under cruise conditions at 7620 (25000 m/ft) altitude. A follow on study extended the results to larger (2500 hp max.) engine sizes suitable for applications such as commuter transports and helicopters. The study engine designs were derived from relevant engine development background including both prior and recent engine test results using direct injected unthrottled rotary engine technology. Aircraft studies, using these resultant growth engines, define anticipated system effects of the performance and power density improvements for both single engine and twin engine airplanes. The calculated results indicate superior system performance and 27 to 33 percent fuel economy improvement for the rotary engine airplanes as compared to equivalent airframe concept designs with current baseline engines. The research and technology activities required to attain the projected engine performance levels are also discussed.
Design studies of advanced multifuel general aviation and commuter aircraft rotary stratified charge engines are summarized. Conceptual design studies were performed at two levels of technology, an advanced general aviation engines sized to provide 186/250 shaft kW/hp under cruise conditions at 7620 (25,000 m/ft) altitude. A follow on study extended the results to larger (2500 hp max.) engine sizes suitable for applications such as commuter transports and helicopters. The study engine designs were derived from relevant engine development background including both prior and recent engine test results using direct injected unthrottled rotary engine technology. Aircraft studies, using these resultant growth engines, define anticipated system effects of the performance and power density improvements for both single engine and twin engine airplanes. The calculated results indicate superior system performance and 27 to 33 percent fuel economy improvement for the rotary engine airplanes as compared to equivalent airframe concept designs with current baseline engines. The research and technology activities required to attain the projected engine performance levels are also discussed. Previously announced in STAR as N83-18910
Preliminary results are presented from an experimental evaluation of a hydrogen-burning wall-injection scramjet engine, performed in the free-piston shock tunnel at the Australian National University. The advantages of scramjet propulsion for high-Mach-number high-altitude flight are reviewed, and the need for an alternative to injection struts is indicated. Pressure profiles and heat-transfer measurements for constant-area and diverging ducts are presented graphically and characterized in detail. The ability of the injected flow to shield the chamber wall from the heat of the freestream flow is demonstrated. The extrapolation of the shock-tunnel results to flight conditions, however, is made difficult by the fact that a significant amount of fuel passes through a quenched zone without burning, seriously degrading overall performance.
An advanced version of the Two-Dimensional Kinetics (TDK) computer program was developed under contract and released to the propulsion community in early 1989. Exposure of the code to this community indicated a need for improvements in certain areas. In particular, the TDK code needed to be adapted to the special requirements imposed by the Space Transportation Main Engine (STME) development program. This engine utilizes injection of the gas generator exhaust into the primary nozzle by means of a set of slots. The subsequent mixing of this secondary stream with the primary stream with finite rate chemical reaction can have a major impact on the engine performance and the thermal protection of the nozzle wall. In attempting to calculate this reacting boundary layer problem, the Mass Addition Boundary Layer (MABL) module of TDK was found to be deficient in several respects. For example, when finite rate chemistry was used to determine gas properties, (MABL-K option) the program run times became excessive because extremely small step sizes were required to maintain numerical stability. A robust solution algorithm was required so that the MABL-K option could be viable as a rocket propulsion industry design tool. Solving this problem was a primary goal of the phase 1 work effort.
The direct-injection stratified-charge (DISC) rotary engine, while attractive for aviation applications due to its light weight, multifuel capability, and potentially low fuel consumption, has until now required a bulky and heavy liquid-cooling system. NASA-Lewis has undertaken the development of a cooling system-obviating, thermodynamically superior adiabatic rotary engine employing state-of-the-art thermal barrier coatings to thermally insulate engine components. The thermal barrier coating material for the cast aluminum, stainless steel, and ductile cast iron components was plasma-sprayed zirconia. DISC engine tests indicate effective thermal barrier-based heat loss reduction, but call for superior coefficient-of-thermal-expansion matching of materials and better tribological properties in the coatings used.
This paper presents an overview of the results of experimental evaluations of candidate designs for igniters, injectors, and propellant-cooled thrust chambers applicable to restartable high-performance, high-reliability upper-stage engines and to pulsing-type reaction control engines (RCE). Injection element types best suited for liquid, gas, and liquid/gas phase propellant supply are identified. The resulting interactions between element type, combustion efficiency, and chamber wall heating are compared. The distinction between thrust chamber design requirements for upper stage vs RCE applications as measured by cycle life requirements is translated into design configurations consisting of all-film-cooled, all-regeneratively-cooled, and composites of the two cooling approaches. The validity of the design approaches is confirmed by data from engine durability testing involving over 90,000 starts and 9,000 thermal cycles on RCE-type designs and multiple long-duration burns (up to 2,000 sec) on regeneratively cooled upper-stage designs.
This paper discusses recovery scenarios for geosynchronous satellites injected in a non-nominal orbit due to a launcher underperformance. The theory on minimum-fuel orbital transfers is applied to develop an operational tool capable to design a recovery mission. To obtain promising initial guesses for the recovery three complementary techniques are used: p-optimized impulse function contouring, a numerical impulse function minimization and the solutions to the switching equations. The tool evaluates the feasibility of a recovery with the on-board propellant of the spacecraft and performs the complete mission design. This design takes into account for various mission operational constraints such as e.g., the requirement of multiple finite-duration burns, third-body orbital perturbations, spacecraft attitude constraints and ground station visibility. In a final case study, we analyze the consequences of a premature breakdown of an upper rocket stage engine during injection on a geostationary transfer orbit, as well as the possible recovery solution with the satellite on-board propellant.
The high hardness of silicon nitride, which is currently under consideration as a structural material for such hot engine components as turbine blades, renders machining of the material prohibitively costly; the near net shape forming technique of injection molding is accordingly favored as a means for component fabrication. Attention is presently given to the relationships between injection molding processing parameters and the resulting microstructural and mechanical properties of the resulting engine parts. An experimental program has been conducted under NASA sponsorship which tests the quality of injection molded bars of silicon nitride at various stages of processing.
Using the method of weighing fuel collected in a receiver during a definite interval of the injection period, rates of discharge were determined, and the effects noted, when various changes were made in a fuel-injection system. The injection system consisted primarily of a by-pass controlled fuel pump and an automatic injection valve. The variables of the system studied were the pump speed, pump-throttle setting, discharge-orifice diameter, injection-valve opening and closing pressures, and injection-tube length and diameter.
Variable displacement fuel pump for internal combustion engines
Design studies, conducted for NASA, of Advanced Multi-fuel General Aviation and Commuter Aircraft Rotary Stratified Charge Engines are summarized. Conceptual design studies of an advanced engine sized to provide 186/250 shaft KW/HP under cruise conditions at 7620/25,000 m/ft. altitude were performed. Relevant engine development background covering both prior and recent engine test results of the direct injected unthrottled rotary engine technology, including the capability to interchangeably operate on gasoline, diesel fuel, kerosene, or aviation jet fuel, are presented and related to growth predictions. Aircraft studies, using these resultant growth engines, define anticipated system effects of the performance and power density improvements for both single engine and twin engine airplanes. The calculated results indicate superior system performance and 30 to 35% fuel economy improvement for the Rotary-engine airplanes as compared to equivalent airframe concept designs with current baseline engines. The research and technology activities required to attain the projected engine performance levels are also discussed.