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NASA NTRS2011

Summary of Results from Space Shuttle Main Engine Off-Nominal Testing

This paper is a summary of Space Shuttle Main Engine (SSME) off-nominal testing that occurred during 2008 and 2009. During the last two years of planned SSME testing at Stennis Space Center, Pratt & Whitney Rocketdyne worked with their NASA MSFC customer to systematically identify, develop, assess, and implement challenging test objectives in order to expand the knowledge of one of the world s most reliable and highly tested large rocket engine. The objectives successfully investigated three main areas of interest expanding engine performance margins, demonstrating system operational capabilities, and establishing ground work for new rocket engine technology. The testing gave the Space Shuttle Program new options to safely fly out the flight manifest and provided Pratt & Whitney Rocketdyne and NASA new insight into the operational capabilities of the SSME, capabilities which can be used in assessing potential future applications of the RS-25 engine.

Horton, James F.↗
NASA NTRS1988

Real-time control for manufacturing space shuttle main engines: Work in progress

During the manufacture of space-based assemblies such as Space Shuttle Main Engines, flexibility is required due to the high-cost and low-volume nature of the end products. Various systems have been developed pursuing the goal of adaptive, flexible manufacturing for several space applications, including an Advanced Robotic Welding System for the manufacture of complex components of the Space Shuttle Main Engines. The Advanced Robotic Welding System (AROWS) is an on-going joint effort, funded by NASA, between NASA/Marshall Space Flight Center, and two divisions of Rockwell International: Rocketdyne and the Science Center. AROWS includes two levels of flexible control of both motion and process parameters: Off-line programming using both geometric and weld-process data bases, and real-time control incorporating multiple sensors during weld execution. Both control systems were implemented using conventional hardware and software architectures. The feasibility of enhancing the real-time control system using the problem-solving architecture of Schemer is investigated and described.

Ruokangas, Corinne C.↗
NASA NTRS1979

Development of the Space Shuttle Main Engine /May 1979/

During the last year, significant progress was made toward the development of the Space Shuttle Main Engine, which will provide propulsion for the Space Shuttle Orbiter vehicle. Engine system testing continued at the National Space Technology Laboratories on both single engines and a three-engine cluster. A third single engine test position was activated at the Rocketdyne Santa Susana Field Laboratory to provide additional capability for demonstrating increasing engine maturity and for solving problems. The results of engine system testing is discussed as well as the major problems identified and the design changes incorporated to solve those problems. A review of the program efforts toward the delivery of the first set of flight engines and the certification of the SSME for manned flight is included.

Colbo, H. I.↗
NASA NTRS1985

Visualizing flow in the Space Shuttle Main Engine

Ongoing work is described aimed at applying advanced post-processing techniques to interpret and understand the complex flow behavior of the Space Shuttle Main Engine. The use of color graphics and powerful new engineering work stations to effectively present massive amounts of numerical data is emphasized. This combination of tools can result in better designs, faster turnaround, and more complete understanding of complex engineering systems like the Shuttle. Furthermore, it allows engineers access to the massive amounts of data generated by supercomputers and provides a more efficient coupling of man and supercomputer.

Belie, R. G.↗
NASA NTRS1982

The reusable Space Shuttle Main Engine prepares for long life

Attention is given to Space Shuttle Main Engine (SSME) life extension and logistical systems that support launch and ground operations. The operations and maintenance tasks involved in this aspect of SSME development include turnaround requirements, ground support equipment, and control documentation. A discussion is presented on the spare parts provisioning system, which emphasizes the source of decision-making data and encompasses the hardware tracking system, usage data from ground testing and launch operations, and current and projected life limits. The life extension test program leads the launch program, offering comfortable life limit margins. Planned overhauls for the extension of useful hardware life beyond the 55-mission requirement, a turnabout improvement program, and a continuous training program contribute to launch cost reductions, reliable operations, and long life.

Klatt, F. P., Jr.↗
NASA NTRS1985

Space Shuttle Main Engine nozzle thermal protection system

Two of the three Space Shuttle Main Engine (SSME) nozzles are exposed to significant reentry aeroheating loads. To ensure reusability of the Nozzle Assembly, the nozzle primary structure must not exceed specific temperature limits. Due to the thermal, pressure, and dynamic flexing of the nozzle during a mission cycle, an appropriate insulating system must have significant flexibility. Recent missions have demonstrated nozzle reentry aeroheating rates and heat loads much higher than predictions, higher than the capability of the original insulating system. A new insulating system has been developed using similar materials in an aerodynamically 'smooth' shape to both reduce the incoming heating and increase radiation cooling.

Nordlund, R. M.↗
NASA NTRS1985

Analysis of cavitation damage on the Space Shuttle main engine high pressure oxidizer turbopump

The performance of the Space Shuttle Main Engines (SSME) has met or exceeded specifications. However, the durability for selected components has not met the desired lifetime criteria. Thus, the High-Pressure Oxidizer Turbopump (HPOTP) has experienced cavitation erosion problems in a number of locations in the pump. An investigation was conducted, taking into account an analysis of the cavitation damage, the development of a flow model for the pump, and the recommendation of design changes which would increase the life expectancy of the unit. The present paper is concerned with the cavitation damage analysis. A model is presented which relates the heavy damage on the housing and over the inducer blades to unsteady blade surface cavitation. This cavitation occurs on the inducer blades in the wakes downstream of the pump inlet housing vanes.

Stinebring, D. R.↗
NASA NTRS1991

Stability testing of a modified Space Shuttle Main Engine

The testing of the combustion stability characteristics of Space Shuttle Main Engine (SSME) 0208 is described in terms of augmenting the technology base for large O/H thrust-chamber assemblies. The throat area is increased by 12 percent over that of the flight SSMEs, and the thrust chamber assembly does not include stability aids. Acoustic modes in the chamber are excited by means of rapid pressure generators employed in the start-transient through mainstage operations. Stability characteristics are determined by damp times which are facilitated by high-frequency instrumentation measuring oscillations and locating stable operating regions. All vibration modes are damped to within the requirements for a chamber mode set forth by the Chemical Propulsion Information Agency. No sustained chamber acoustic oscillations are exhibited in engine 0208's combustion chamber configuration in spite of the absence of baffles and acoustic cavities.

Dennis, H.↗
NASA NTRS1991

High-frequency data observations from space shuttle main engine low pressure fuel turbopump discharge duct flex joint tripod failure investigation

Observations made by Marshall Space Flight Center (MSFC) engineers during their participation in the Space Shuttle Main Engine (SSME) low pressure fuel turbopump discharge duct flex joint tripod failure investigation are summarized. New signal processing techniques used by the Component Assessment Branch and the Induced Environments Branch during the failure investigation are described in detail. Moreover, nonlinear correlations between frequently encountered anomalous frequencies found in SSME dynamic data are discussed. A recommendation is made to continue low pressure fuel (LPF) duct testing through laboratory flow simulations and MSFC-managed technology test bed SSME testing.

Zoladz, T. F.↗
NASA NTRS1991

A simplified dynamic model of Space Shuttle Main Engine

A simplified dynamic model is presented of the Space Shuttle Main Engine (SSME) dynamics valid within the range of operation of the engine. This model is obtained by linking the linearized point models obtained at 25 different operating points of SSME. The simplified model was developed for use with a model-based diagnostic scheme for failure detection and diagnostics studies, as well as control design purposes.

Duyar, Ahmet↗
NASA NTRS1990

Test Results of the Modified Space Shuttle Main Engine at the Marshall Space Flight Center Technology Test Bed Facility

A modified space shuttle main engine (SSME), which primarily includes an enlarged throat main combustion chamber with the acoustic cavities removed and a main injector with the stability control baffles removed, was tested. This one-of-a-kind engine's design changes are being evaluated for potential incorporation in the shuttle flight program in the mid-1990's. Engine testing was initiated on September 15, 1988 and has accumulated 1,915 seconds and 19 starts. Testing is being conducted to characterize the engine system performance, combustion stability with the baffle-less injector, and both low pressure oxidizer turbopump (LPOTP) and high pressure oxidizer turbopump (HPOTP) for suction performance. These test results are summarized and compared with the SSME flight configuration data base. Testing of this new generation SSME is the first product from the technology test bed (TTB). Figure test plans for the TTB include the highly instrumented flight configuration SSME and advanced liquid propulsion technology items.

Cook, J.↗
NASA NTRS1974

Space Shuttle OMS engine valve technology

Valve technology program to determine shutoff valve concepts suitable for the Orbital Maneuvering System (OMS) engine of the Space Shuttle. The tradeoff studies selected the electric torque motor operated dual poppet and ball valves as the most desirable valve concepts for the OMS Engine Shutoff Valve. A prototype of one of these concepts was built and subjected to a design verification program. A number of unique features were designed to include the required contamination insensitivity, operating fluid compatibility, decontamination capability, minimum maintenance requirement and long service life capability.

Wichmann, H.↗
NASA NTRS1981

Space Shuttle main engine progress through the first flight

A system overview is presented for the Space Shuttle Main Engine (SSME), and extensive performance comparisons are made with the Saturn V booster powerplant showing (1) staged-combustion turbopump pressures of 7,500 vs 1,100 psi for the Saturn V first stage; (2) a specific impulse of 455 vs 300; (3) power density of 100 vs 20 hp/lb; and (4) chamber pressures of 3200 vs 1000 psia. An account is then given of the SSME testing program, engine certification process and flight aboard the Space Shuttle Columbia, with attention to anomalies detected during flight in turbopump operation and mixture ratio sensor function.

Johnson, J. R.↗
NASA NTRS1981

Space Shuttle main engine performance assessment - Columbia's first flight

Design features and performance of the Shuttle main engines first flight are presented. Each of the three engines produces 470,000 lb of thrust, operates at 3,012 psia, and has a 77.5 to 1 nozzle expansion ratio. The engines are designed for a 7.5 hr operational life, and will be tested at 109% capacity in future Shuttle flights. The developmental program is outlined, and includes 127,000 sec of operational testing on 19 engines. Engine operations and components are described, noting 100% burning of the hydrogen and oxidizer, high pressure fuel turbopumps, the controller assembly, etc.; details of solutions to fatigue failures and subsequent certification are provided. The nine minute first flight firing revealed a radiant heating of a control sensor transducer, which was shielded for succeeding flights. Alternatives are given for thrust augmentation, for which each 1% yields an additional 800 lb payload increase capability, and can be implemented by 1987.

Thompson, J. R., Jr.↗
NASA NTRS1981

Space Shuttle main engine nozzle-steerhorn dynamics

On two occasions during the Space Shuttle main engine development, the LH2 feedline (called the steerhorn, because of its shape) failed during the cutoff transient. A dynamic test was undertaken, and an analytical model was developed and correlated to the dynamic test. Detailed models of the tube bundle were required to obtain the equivalent shell coefficients. All-shell models of the nozzle wall were found better than beam-shell models. The most difficult part of the structure to simulate was the felt-metal pad between the feedline and its mount, which introduced nonlinear stiffness and damping and led to the use of separate low amplitude and high amplitude models. The total structure was found to have 400 modes in the frequency range of interest, 0 to 500 Hz. Good test analysis correlation was obtained and a modified feedline configuration was found to demonstrate a 40% reduction of response stress from the original configuration.

Kiefling, L.↗
NASA NTRS1999

Space Shuttle Main Engine: Advanced Health Monitoring System

The main gola of the Space Shuttle Main Engine (SSME) Advanced Health Management system is to improve flight safety. To this end the new SSME has robust new components to improve the operating margen and operability. The features of the current SSME health monitoring system, include automated checkouts, closed loop redundant control system, catastropic failure mitigation, fail operational/ fail-safe algorithms, and post flight data and inspection trend analysis. The features of the advanced health monitoring system include: a real time vibration monitor system, a linear engine model, and an optical plume anomaly detection system. Since vibration is a fundamental measure of SSME turbopump health, it stands to reason that monitoring the vibration, will give some idea of the health of the turbopumps. However, how is it possible to avoid shutdown, when it is not necessary. A sensor algorithm has been developed which has been exposed to over 400 test cases in order to evaluate the logic. The optical plume anomaly detection (OPAD) has been developed to be a sensitive monitor of engine wear, erosion, and breakage.

Singer, Chirs↗
NASA NTRS1976

Annual report to the NASA Administrator by the Aerospace Safety Advisory Panel on the space shuttle program. Part 2: Summary of information developed in the panel's fact-finding activities

Safety management areas of concern include the space shuttle main engine, shuttle avionics, orbiter thermal protection system, the external tank program, and the solid rocket booster program. The ground test program and ground support equipment system were reviewed. Systems integration and technical 'conscience' were of major priorities for the investigating teams.

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