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NASA NTRS2006

Cold Flow Testing for Liquid Propellant Rocket Injector Scaling and Throttling

Scaling and throttling of combustion devices are important capabilities to demonstrate in development of liquid rocket engines for NASA's Space Exploration Mission. Scaling provides the ability to design new injectors and injection elements with predictable performance on the basis of test experience with existing injectors and elements, and could be a key aspect of future development programs. Throttling is the reduction of thrust with fixed designs and is a critical requirement in lunar and other planetary landing missions. A task in the Constellation University Institutes Program (CUIP) has been designed to evaluate spray characteristics when liquid propellant rocket engine injectors are scaled and throttled. The specific objectives of the present study are to characterize injection and primary atomization using cold flow simulations of the reacting sprays. These simulations can provide relevant information because the injection and primary atomization are believed to be the spray processes least affected by the propellant reaction. Cold flow studies also provide acceptable test conditions for a university environment. Three geometric scales - 1/4- scale, 1/2-scale, and full-scale - of two different injector element types - swirl coaxial and shear coaxial - will be designed, fabricated, and tested. A literature review is currently being conducted to revisit and compile the previous scaling documentation. Because it is simple to perform, throttling will also be examined in the present work by measuring primary atomization characteristics as the mass flow rate and pressure drop of the six injector element concepts are reduced, with corresponding changes in chamber backpressure. Simulants will include water and gaseous nitrogen, and an optically accessible chamber will be used for visual and laser-based diagnostics. The chamber will include curtain flow capability to repress recirculation, and additional gas injection to provide independent control of the backpressure. This paper provides a short review of the appropriate literature, as well as descriptions of plans for experimental hardware, test chamber instrumentation, diagnostics, and testing.

Kenny, Jeremy R.↗

NASA NTRS2006

Local Heat Flux Measurements with Single and Small Multi-element Coaxial Element-Injectors

To support NASA's Vision for Space Exploration mission, the NASA Marshall Space Flight Center conducted a program in 2005 to improve the capability to predict local thermal compatibility and heat transfer in liquid propellant rocket engine combustion devices. The ultimate objective was to predict and hence reduce the local peak heat flux due to injector design, resulting in a significant improvement in overall engine reliability and durability. Such analyses are applicable to combustion devices in booster, upper stage, and in-space engines with regeneratively cooled chamber walls, as well as in small thrust chambers with few elements in the injector. In this program, single and three-element injectors were hot-fire tested with liquid oxygen and gaseous hydrogen propellants at The Pennsylvania State University Cryogenic Combustor Laboratory from May to August 2005. Local heat fluxes were measured in a 1-inch internal diameter heat sink combustion chamber using Medtherm coaxial thermocouples and Gardon heat flux gauges, Injector configurations were tested with both shear coaxial elements and swirl coaxial elements. Both a straight and a scarfed single element swirl injector were tested. This paper includes general descriptions of the experimental hardware, instrumentation, and results of the hot-fire testing for three coaxial shear and swirl elements. Detailed geometry and test results the for shear coax elements has already been published. Detailed test result for the remaining 6 swirl coax element for the will be published in a future JANNAF presentation to provide well-defined data sets for development and model validation.

Jones, Gregg↗

NASA NTRS2010

Coaxial Injectors for Liquid Oxygen/Methane (LOX/CH4) Technology Development

Since late 2005, NASA s Marshall Space Flight Center (MSFC) has been developing and demonstrating technology for liquid oxygen and methane (LOX/CH4) engine designs. Efforts were undertaken to help advance technology that might benefit NASA s Exploration Technology Development Program. The propellant combination has gained interest as a potential option for the ascent stage main propulsion system on the Altair lunar lander vehicle. The propellants are also attractive for eventual Mars missions in future development activities. MSFC s efforts focus on evaluating the performance potential of both liquid and gaseous methane for specific injector designs. Previous JANNAF papers reported the performance observed for LOX and methane with an impinging injector. More recent efforts have focused on testing coaxial injector designs. Hot-fire testing performed at MSFC with thrust levels close to 5000 lbf demonstrated high performance with coaxial injectors of different element densities and various fuel film cooling levels. Test data provided results on performance, chamber wall compatibility, and heat flux profiles for different injectors. A variety of igniters were also demonstrated, including a torch igniter and a microwave (or plasma) igniter.

Elam, Sandra↗

NASA NTRS1959

The Effect of Rapid Liquid-Phase Reactions on Injector Design and Combustion in Rocket Motors

Data are presented indicating the rates and magnitudes of energy released by the liquid-phase reactions of various propellant combinations. The data show that this energy release can contribute significantly to the rate of vaporization of the incoming propellants and thus aid the combustion process. Nevertheless, very low performances were obtained in rocket motors with conventional impinging-jet injectors when highly reactive systems such as N104-N2H4, were employed. A possible explanation for this low performance is that the initial reactions of such systems are so rapid that liquid-phase mixing is inhibited. Evidence for such an effect is presented in a series of color photographs of open flames using various injector elements. Based on these studies, some requirements are suggested for injector elements using highly reactive propellants. Experimental results are presented of motor tests using injector elements in which some of these requirements are met through the use of a set of concentric tubes. These tests, carried out at thrust levels of 40 to 800 lb per element, demonstrated combustion efficiencies of up to 98% based on equilibrium characteristic velocity values. Results are also presented for tests made with impinging-jet and splash-plate injectors for comparison.

Elverum, Gerard W., Jr.↗

NASA NTRS1968

Fundamental problems of injector design

The principal control of the combustion within a liquid-propellant rocket thrust chamber is provided by the injector. Only when precise control of the injection process is attained can optimum performance, dynamic stability, heat transfer compatibility and reproducibility be provided. Control must be designed into each step of the injection process with sufficient isolation provided to insure stability. In the design of the injector manifolding, the main desire is to provide mass and mixture ratio regulation across the injector face. The design of the injector orifices must be such that this mass and mixture ratio control is retained through the orifices and imparted to the droplet sprays that are produced. Furthermore, the orifice design must control the size and distribution of the droplets generated so that combustion will be completed within the chamber. Mechanical damping devices are often required to protect the early mixing zone from transverse velocities and associated displacement effects in the chamber. Only when each phase of the injection process is carefully controlled can the design aims be reached.

David T Harrje↗

NASA NTRS1972

Oxygen-hydrogen injector performance and compatibility with ablative chambers

An experimental investigation was conducted to develop a high-thrust, high-performance, concentric tube injector element for use with near liquid hydrogen and liquid oxygen propellants. A parallel tube coaxial injector yielded 98 percent theoretical characteristic exhaust velocity efficiency. Installation of swirlers in the oxidizer tube improved performance but caused high ablative erosion near the injector. Film cooling significantly reduced ablative erosion near the injector but did not completely alleviate gouging adjacent to each outer injection element.

Wanhainen, J. P.↗

NASA NTRS1972

Space storable propellant performance program coaxial injector characterization

An experimental program was conducted to characterize the circular coaxial injector concept for application with the space-storable gas/liquid propellant combination FLOX(82.6% F2)/CH4(g) at high pressure. The primary goal of the program was to obtain high characteristic velocity efficiency in conjunction with acceptable injector/chamber compatibility. A series of subscale (single element) cold flow and hot fire experiments was employed to establish design criteria for a 3000-lbf (sea level) engine operating at 500 psia. The subscale experiments characterized both high performance core elements and peripheral elements with enhanced injector/chamber compatibility. The full-scale injector which evolved from the study demonstrated a performance level of 99 percent of the theoretical shifting characteristic exhaust velocity with low chamber heat flux levels. A 44-second-duration firing demonstrated the durability of the injector. Parametric data are presented that are applicable for the design of circular, coaxial injectors that operate with injection dynamics (fuel and oxidizer velocity, etc.) similar to those employed in the work reported.

Burick, R. J.↗

NASA NTRS1973

Gas velocity and temperature near a liquid rocket injector face

The gas flow near the injector of a liquid propellant rocket was investigated by rapidly inserting butt-welded platinum-platinum rhodium thermocouples through the injector into the chamber. The transient responses of the thermocouples were analyzed to determine average gas temperatures and velocities. A method of fitting exponential curves to repeated measurements of the transient temperature at several positions near the injector face produced consistent results. Preliminary tests yielded gas flow directions and gas compositions at the injector face. Average gas temperatures were found to be between 3100 (1700) and 3500 F (1950 C) and the average gas velocities between 550 (170) and 840 feet/second (260 m/sec).

Boylan, D. M.↗

NASA NTRS1973

Injector design guidelines for gas/liquid propellant systems

Injector design guidelines are provided for gas/liquid propellant systems. Information was obtained from a 30-month applied research program encompassing an analytical, design, and experimental effort to relate injector design parameters to simultaneous attainment of high performance and component (injector/thrust chamber) compatibility for gas/liquid space storable propellants. The gas/liquid propellant combination studied was FLOX (82.6% F2)/ ambient temperature gaseous methane. Design criteria that provide for simultaneous attainment of high performance and chamber compatibility are presented for both injector types. Parametric data are presented that are applicable for the design of circular coaxial and like-doublet injectors that operate with design parameters similar to those employed. However, caution should be exercised when applying these data to propellant combinations whose elements operate in ranges considerably different from those employed in this study.

Falk, A. Y.↗

NASA NTRS1974

Exploratory tests of two strut fuel injectors for supersonic combustion

Results of supersonic mixing and combustion tests performed with two simple strut injector configurations, one with parallel injectors and one with perpendicular injectors, are presented and analyzed. Good agreement is obtained between static pressure measured on the duct wall downstream of the strut injectors and distributions obtained from one-dimensional calculations. Measured duct heat load agrees with results of the one-dimensional calculations for moderate amounts of reaction, but is underestimated when large separated regions occur near the injection location. For the parallel injection strut, good agreement is obtained between the shape of the injected fuel distribution inferred from gas sample measurements at the duct exit and the distribution calculated with a multiple-jet mixing theory. The overall fraction of injected fuel reacted in the multiple-jet calculation closely matches the amount of fuel reaction necessary to match static pressure with the one-dimensional calculation. Gas sample measurements with the perpendicular injection strut also give results consistent with the amount of fuel reaction in the one-dimensional calculation.

Anderson, G. Y.↗

NASA NTRS1974

Drag and distribution measurements of single-element fuel injectors for supersonic combustors

The drag caused by several vortex generating fuel injectors for scramjet combustors was measured in a Mach 2 to 3.5 airstream. Injector drag was found to be strongly dependent on injector thickness ratio. The distribution of helium injected into the stream was measured both in the near field and the far field of the injectors for a variety of pressure ratios. The far field results differed appreciably from measurements in the near field. Injection pressure ratio was found to profoundly influence the penetration. One of the aerowing configurations tested yielded low drag consistent with desirable penetration and spreading characteristics.

Povinelli, L. A.↗

NASA NTRS1974

Experimental evaluation of an injector system for powering a high Reynolds number transonic wind tunnel

The problems of powering a large, high-Reynolds number transonic wind tunnel are briefly reviewed, and the advantages of an injector drive system are presented. This paper is based on the results of an experimental investigation of a series of injector configurations and test variables using a pilot wind tunnel with a 6-in.-diameter test section. The purpose of this investigation is to determine the efficiency and flow quality of an injector driven wind tunnel and develop configurations that will reduce the initial cost of a wind tunnel without seriously reducing efficiency and flow quality. The results indicate that high efficiencies can be obtained and that injector drive does not compromise flow quality in a transonic wind tunnel.

Muhlstein, L., Jr.↗

NASA NTRS1975

Combustor exhaust emissions with air-atomizing splash-groove fuel injectors burning Jet A and Diesel number 2 fuels

Air-atomizing, splash-groove injectors were shown to improve primary-zone fuel spreading and reduce combustor exhaust emissions for Jet A and diesel number 2 fuels. With Jet A fuel large-orifice, splash-groove injectors the oxides-of-nitrogen emission index was reduced, but emissions of carbon monoxide, unburned hydrocarbons, or smoke were unaffected. Small-orifice, splash-groove injectors did not reduce oxides of nitrogen, but reduced the smoke number and carbon monoxide and unburned-hydrocarbon emission indices. With diesel number 2 fuel, the small-orifice, splash-groove injectors reduced oxides of nitrogen by 19 percent, smoke number by 28 percent, carbon monoxide by 75 percent, and unburned hydrocarbons by 50 percent. Smoke number and unburned hydrocarbons were twice as high with diesel number 2 as with Jet A fuel. Combustor blowout limits were similar for diesel number 2 and Jet A fuels.

Ingebo, R. D.↗

NASA NTRS1975

Coaxial injector response to axial instability under simulated cold-flow

The frequency dependence of the admittances and response factors of various gaseous rocket injector configurations subject to axial instabilities under cold-flow conditions, have been measured using the modified impedance-tube technique. The tested configurations simulate the flows in a gaseous-fuel injector, gaseous-oxidizer injector and a coaxial injector with both fuel and oxidizer elements. Comparison of the measured response data with corresponding data predicted by the Feiler and Heidmann model indicates good agreement between the two sets of data.

Janardan, B. A.↗

NASA NTRS1975

Space shuttle orbital maneuvering engine platelet injector program

A platelet face injector for the Orbit Maneuvering Engine (OME) on the space shuttle was evaluated as a means of obtaining additional design margin and lower cost. The program was conducted in three phases. The first phase evaluated single injection elements, or unielements; it involved visual flow studies, mixing experiments using propellant simulants, and hot firings to assess combustion efficiency, chamber wall compatibility, and injector face temperatures. In the second phase, subscale units producing 600 lbf thrust were used to further evaluate the orifice patterns chosen on the basis of unielement testing. In addition to combustion efficiency, chamber and injector heat transfer, the subscale testing provided a preliminary indication of injector stability. Full scale testing of the selected patterns at 6,000 lbf thrust was performed in the third phase. Performance, heat transfer, and combustion stability were evaluated over the anticipated range of OMS operating conditions. The effects on combustion stability of acoustic cavity configuration, including cavity depth, open area, inlet contour, and other parameters, were investigated.

Source record↗

NASA NTRS1978

Interaction between step fuel injectors on opposite walls in a supersonic combustor model

Results are presented from an experimental investigation of perpendicular, hydrogen fuel injection and combustion from opposing walls in a scramjet combustor model using a longitudinally staged laterally inline step-injection configuration. The model represents a portion of the flow in the Langley integrated modular scramjet engine combustor operating at a flight Mach number of 7. When operating at a ratio of jet pressure to free-stream dynamic pressure of 3, the injectors produce a bulk equivalence ratio of unity. This investigation represents part of a continuing study of the modular engine fuel injectors and is specifically designed to eliminate the adverse lateral pressure gradient observed at the injector location in a previous test. Flow survey contours at three axial locations, ranging from one-third of the engine combustor length to the total engine combustor length, are used to determine mixing efficiency and fuel distribution. Wall static pressures are analyzed by using one-dimensional theory to determine the combustion efficiency. Results show a significant improvement over previous injector designs tested in this duct geometry.

Mcclinton, C. R.↗

NASA NTRS1977

Direct-connect test of a hydrogen-fueled three-strut injector for an integrated modular scramjet engine

The study aims at illustrating the effects of strut and injector interactions and strut wakes not totally simulated in previous, less complex, direct-connect hardware. In addition, the influence of the relative location of the injectors on opposite sides of each strut and the effect of injector spacing are evaluated. It is shown that better mixing efficiency is attained by locating the fuel injectors on opposite sides of a strut so that the jets come together, rather than being staggered, in the strut wake. It is not possible to determine the combustion efficiency by means of a one-dimensional analysis of the wall pressure.

Mcclinton, C. R.↗

NASA NTRS1979

A zero G fluid drop injector for the drop dynamics module spacelab experiment

A fluid drop injector was developed to form and release fluid drops into free drift within an experimental apparatus known as the Drop Dynamics Module which is to be flown on an earth orbiting Spacelab. To verify the design concept, a breadboard injector was flown on the NASA KC-135 zero g airplane after which more extensive laboratory 1 g tests were performed to improve the injector design and enable it to meet the module's functional requirements. The breadboard fluid drop injector will be modified and upgraded to flight hardware.

Holtz, G. M.↗