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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 109 records · Page 6

Thermal Barrier Coatings

In order to reduce heat transfer between a hot gas heat source and a metallic engine component, a thermal insulating layer of material is placed between them. This thermal barrier coating is applied by plasma spray processing the thin films. The coating has been successfully employed in aerospace applications for many years. Lewis Research Center, a leader in the development engine components coating technology, has assisted Caterpillar, Inc. in applying ceramic thermal barrier coatings on engines. Because these large engines use heavy fuels containing vanadium, engine valve life is sharply decreased. The barrier coating controls temperatures, extends valve life and reduces operating cost. Additional applications are currently under development.

Source record↗

Effect of Fuel Injection and Mixing Characteristics on Pulse-Combustor Performance at High-Pressure

Recent calculations of pulse-combustors operating at high-pressure conditions produced pressure gains significantly lower than those observed experimentally and computationally at atmospheric conditions. The factors limiting the pressure-gain at high-pressure conditions are identified, and the effects of fuel injection and air mixing characteristics on performance are investigated. New pulse-combustor configurations were developed, and the results show that by suitable changes to the combustor geometry, fuel injection scheme and valve dynamics the performance of the pulse-combustor operating at high-pressure conditions can be increased to levels comparable to those observed at atmospheric conditions. In addition, the new configurations can significantly reduce the levels of NOx emissions. One particular configuration resulted in extremely low levels of NO, producing an emission index much less than one, although at a lower pressure-gain. Calculations at representative cruise conditions demonstrated that pulse-combustors can achieve a high level of performance at such conditions.

Propulsion↗

Preliminary input to the space shuttle reaction control subsystem failure detection and identification software requirements (uncontrolled)

The current baseline method and software implementation of the space shuttle reaction control subsystem failure detection and identification (RCS FDI) system is presented. This algorithm is recommended for conclusion in the redundancy management (RM) module of the space shuttle guidance, navigation, and control system. Supporting software is presented, and recommended for inclusion in the system management (SM) and display and control (D&C) systems. RCS FDI uses data from sensors in the jets, in the manifold isolation valves, and in the RCS fuel and oxidizer storage tanks. A list of jet failures and fuel imbalance warnings is generated for use by the jet selection algorithm of the on-orbit and entry flight control systems, and to inform the crew and ground controllers of RCS failure status. Manifold isolation valve close commands are generated in the event of failed on or leaking jets to prevent loss of large quantities of RCS fuel.

Bergmann, E.↗

Study of fuel systems for LH2-fueled subsonic transport aircraft, volume 1

Several engine concepts examined to determine a preferred design which most effectively exploits the characteristics of hydrogen fuel in aircraft tanks received major emphasis. Many candidate designs of tank structure and cryogenic insulation systems were evaluated. Designs of all major elements of the aircraft fuel system including pumps, lines, valves, regulators, and heat exchangers received attention. Selected designs of boost pumps to be mounted in the LH2 tanks, and of a high pressure pump to be mounted on the engine were defined. A final design of LH2-fueled transport aircraft was established which incorporates a preferred design of fuel system. That aircraft was then compared with a conventionally fueled counterpart designed to equivalent technology standards.

Brewer, G. D.↗

Influence of several factors on ignition lag in a compression-ignition engine

This investigation was made to determine the influence of fuel quality, injection advance angle, injection valve-opening pressure, inlet-air pressure, compression ratio, and engine speed on the time lag of auto-ignition of a Diesel fuel oil in a single-cylinder compression-ignition engine as obtained from an analysis of indicator diagrams. Three cam-operated fuel-injection pumps, two pumps cams, and an automatic injection valve with two different nozzles were used. Ignition lag was considered to be the interval between the start of injection of the fuel as determined with a Stroborama and the start of effective combustion as determined from the indicator diagram, the latter being the point where 4.0 x 10(exp-6) pound of fuel had been effectively burned. For this particular engine and fuel it was found that: (1) for a constant start and the same rate of fuel injection up the point of cut-off, a variation in fuel quantity from 1.2 x 10(exp-4) to 4.1 x 10(exp-4) pound per cycle has no appreciable effect on the ignition lag; (2) injection advance angle increases or decreases the lag according to whether density, temperature, or turbulence has the controlling influence; (3) increase in valve-opening pressure slightly increases the lag; and (4) increase of inlet-air pressure, compression ratio, and engine speed reduces the lag.

Gerrish, Harold C↗

The Effect of Valve Cooling upon Maximum Permissible Engine Output as Limited by Knock

A Wright GR-1820-G200 cylinder was tested over a wide range of fuel-air ratios at maximum permissible power output as limited by knock with three different degrees of valve cooling. The valves used were stock valves (solid inlet valve and hollow sodium-cooled exhaust valve), hollow valves with no coolant, and hollow valves with flowing water as a coolant. Curves showing the variation in maximum permissible values of inlet-air pressure, indicated mean effective pressure, cylinder charge, and indicated specific fuel consumption with change in fuel-air ratio and valve cooling are shown. The use of valves cooled by a stream of water passing through their hollow interiors permitted indicated mean effective pressures 10 percent higher than the mean effective pressures permissible with stock valves when the engine was operated with fuel-air ratios from 0.055 to 0.065. Operation of the engine with lean mixtures with uncooled hollow valves resulted in power output below the output obtained with the stock valves. The data show an increase in maximum permissible indicated mean effective pressure due to cooling the valves, which averages only 2.1 percent with fuel-air ratios from 0.075 to 0.105.

Munger, Maurice↗

The Design and Development of an Automatic Injection Valve with an Annular Orifice of Varying Area

The purpose of this investigation was to provide an automatic injection valve of simple construction which would produce a finely atomized oil spray of broad cone angle and would fulfill the requirements of fuel injection in aircraft oil engines. The injection valve designed has only six parts - i. e., two concentric nozzle tubes flared at one end, two body parts, and two nuts. Analysis and engine tests indicate that the fuel spray from this type of injection valve has characteristics which reduce the time lag of autoignition and promote efficient combustion in high-speed oil engines.

Joachim, William F↗

Garter Valves

Small subvalves opened and closed simultaneously. Precisely-machined mating rings act as valves. Rings seal against each other to stop fluid flow. Rings deformed or moved relative to each other to uncover holes and permit flow. Valve controls flow rate of fuel into burner.

Jencek, P.↗

Analysis of the STS-126 Flow Control Valve Structural-Acoustic Coupling Failure

During the Space Transportation System mission STS-126, one of the main engine's flow control valves incurred an unexpected failure. A section of the valve broke off during liftoff. It is theorized that an acoustic mode of the flowing fuel, coupled with a structural mode of the valve, causing a high cycle fatigue failure. This report documents the analysis efforts conducted in an attempt to verify this theory. Hand calculations, computational fluid dynamics, and finite element methods are all implemented and analyses are performed using steady-state methods in addition to transient analysis methods. The conclusion of the analyses is that there is a critical acoustic mode that aligns with a structural mode of the valve

Jones, Trevor M.↗

Effect of High Air Velocities on the Distribution and Penetration of a Fuel Spray

By means of the NACA Spray Photography Equipment high speed moving pictures were taken of the formation and development of fuel sprays from an automatic injection valve. The sprays were injected normal to and counter to air at velocities from 0 to 800 feet per second. The air was at atmosphere temperature and pressure. The results show that high air velocities are an effective means of mixing the fuel spray with the air during injection.

Rothrock, A M↗

The Effects of Fuel and Cylinder Gas Densities on the Characteristics of Fuel Sprays for Oil Engines

This investigation was conducted as a part of a general research on fuel-injection engines for aircraft. The purpose of the investigation was to determine the effects of fuel and cylinder gas densities with several characteristics of fuel sprays for oil engines. The start, growth, and cut-off of single fuel sprays produced by automatic injection valves were recorded on photographic film by means of special high-speed motion-picture apparatus. This equipment, which has been described in previous reports, is capable of taking twenty-five consecutive pictures of the moving spray at the rate of 4,000 per second. The penetrations of the fuel sprays increased and the cone angles and relative distributions decreased with increase in the specific gravity of the fuel. The density of the gas into which the fuel sprays were injected controlled their penetration. This was the only characteristic of the chamber gas that had a measurable effect upon the fuel sprays. Application of fuel-spray penetration data to the case of an engine, in which the pressure is rising during injection, indicated that fuel sprays may penetrate considerably farther than when injected into a gas at a density equal to that of the gas in an engine cylinder at top center.

Joachim, W F↗

Operating Temperatures of a Sodium-Cooled Exhaust Valve as Measured by a Thermocouple

A thermocouple was installed in the crown of a sodium-cooled exhaust valve. The valve was then tested in an air-cooled engine cylinder and valve temperatures under various engine operating conditions were determined. A temperature of 1337 F was observed at a fuel-air ratio of 0.064, a brake mean effective pressure of 179 pounds per square inch, and an engine speed of 2000 rpm. Fuel-air ratio was found to have a large influence on valve temperature, but cooling-air pressure and variation in spark advance had little effect. An increase in engine power by change of speed or mean effective pressure increased the valve temperature. It was found that the temperature of the rear spark-plug bushing was not a satisfactory indication of the temperature of the exhaust valve.

FUEL-AIR MIXTURES↗

Fuel injector design for high temperature aircraft engine

The objective of the Innovative High Temperature Aircraft Engine Fuel Nozzle Program was to design and evaluate a nozzle capable of operating at a combustor inlet air temperature of 1600 F (1144 K) and a fuel temperature of 350 F (450 K). The nozzle was designed to meet the same performance requirements and fit within the size envelope of a current production dual orifice fuel nozzle. The design approach was to use improved thermal protection and fuel passage geometry in combination with fuel passage surface treatment to minimize coking at these extreme fuel and air temperatures. Heat transfer models of several fuel injector concepts were used to optimize the thermal protection, while sample tube coking tests were run to evaluate the effect of surface finish, coatings and tube material on the coking rate. Based on heat transfer analysis, additional air gaps, reduced fuel passage flow area and use of ceramic tip components reduced local fuel wetted wall temperatures by more than 200 F (100 K) when compared to a current production fuel nozzle. Sample tube coking test results showed the importance of surface finish on the fuel coking rate. Therefore, a one micro-inch (0.025 micron) roughness was specified for all fuel passage surfaces. A novel flow divider valve in the tip was also employed to reduce weight, allow room for additional thermal protection, and provide back pressure to reduce the risk of fuel vaporization. The fuel nozzle was fabricated and evaluated in a series of high temperature coking tests. Initial results of these tests indicate that thermal protection and surface treatments were partially successful in preventing nozzle fouling, but additional refinement of the internal flowpath is needed to prevent buildup of coke particles that partially blocked the spin slots which meter the nozzle fuel flow.

R. W. Stickles↗

Test-Analysis Modal Correlation of Rocket Engine Structures in Liquid Hydrogen - Phase II

Many structures in a launch vehicle operate in liquid hydrogen, from the hydrogen fuel tanks through the ducts and valves and into the turbopumps. Calculating the structural dynamic response of these structures is critical for successful qualification, but accurate knowledge of the natural frequencies is based entirely on numerical or analytical predictions since testing in operating conditions is problematic. A comprehensive test/analysis program has therefore been performed at NASA/MSFC to enable accurate prediction of the modal characteristics of the Space Launch System’s (SLS) RS-25 Low Pressure Fuel Turbopump Inducer including the effects of fluid-added mass, mechanical property change at cryogenic temperatures, operation within tight tip clearances, acoustic/structure interaction, and hydroelasticity. The process also has to account for complicated cyclic symmetry mode shapes which can be easily mistuned in test, and geometric, boundary condition, and material modifications between the sub-scale inducer used as a test article and the actual flight component. The first phase of the program, documented previously, focused on testing of a cantilever beam in a number of fluids and temperatures to isolate the effects of fluid-added mass and temperature, while the second phase reported here documents the additional issues associated with the more realistic inducer test article. Preliminary structural dynamic analysis of the flight hardware including variability for the above parameters indicated potential severe resonances, requiring implementation of undesired programmatic constraints, so the improved predictive capability may allow removal of these constraints.

Brown, Andrew M.↗

Active Suppression of Instabilities in Engine Combustors

A method of feedback control has been proposed as a means of suppressing thermo-acoustic instabilities in a liquid- fueled combustor of a type used in an aircraft engine. The basic principle of the method is one of (1) sensing combustor pressure oscillations associated with instabilities and (2) modulating the rate of flow of fuel to the combustor with a control phase that is chosen adaptively so that the pressure oscillations caused by the modulation oppose the sensed pressure oscillations. The need for this method arises because of the planned introduction of advanced, lean-burning aircraft gas turbine engines, which promise to operate with higher efficiencies and to emit smaller quantities of nitrogen oxides, relative to those of present aircraft engines. Unfortunately, the advanced engines are more susceptible to thermoacoustic instabilities. These instabilities are hard to control because they include large dead-time phase shifts, wide-band noise characterized by amplitudes that are large relative to those of the instabilities, exponential growth of the instabilities, random net phase walks, and amplitude fluctuations. In this method (see figure), the output of a combustion-pressure sensor would be wide-band-pass filtered and then further processed to generate a control signal that would be applied to a fast-actuation valve to modulate the flow of fuel. Initially, the controller would rapidly take large phase steps in order to home in, within a fraction of a second, to a favorable phase region within which the instability would be reduced. Then the controller would restrict itself to operate within this phase region and would further restrict itself to operate within a region of stability, as long as the power in the instability signal was decreasing. In the phase-shifting scheme of this method, the phase of the control vector would be made to continuously bounce back and forth from one boundary of an effective stability region to the other. Computationally, this scheme would be implemented by the adaptive sliding phaser averaged control (ASPAC) algorithm, which requires very little detailed knowledge of the combustor dynamics. In the ASPAC algorithm, the power of the instability signal would be calculated from the wide-bandpass- filtered combustion-pressure signal and averaged over a period of time (typically of the order of a few hundredths of a second) corresponding to the controller updating cycle [not to be confused with the controller sampling cycle, which would be much shorter (typically of the order of 10(exp -4) second)].

Kopasakis, George↗

In-tank shutoff valve is provided with maximum blast protection

In-tank shutoff valve is installed with the valve poppet and actuator inside the tank to provide maximum blast protection during rocket engine test operation. This valve design is applicable wherever explosive fuels are used and is currently being used in lox and liquid hydrogen tanks at a rocket engine test site.

Holden, C. F.↗

Study of advanced techniques for determining the long term performance of components

The application of existing and new technology to the problem of determining the long-term performance capability of liquid rocket propulsion feed systems is discussed. The long term performance of metal to metal valve seats in a liquid propellant fuel system is stressed. The approaches taken in conducting the analysis are: (1) advancing the technology of characterizing components through the development of new or more sensitive techniques and (2) improving the understanding of the physical of degradation.

Source record↗