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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Aerothermal Ground Testing of Flexible Thermal Protection Systems for Hypersonic Inflatable Aerodynamic Decelerators

Flexible TPS development involves ground testing and analysis necessary to characterize performance of the FTPS candidates prior to flight testing. This paper provides an overview of the analysis and ground testing efforts performed over the last year at the NASA Langley Research Center and in the Boeing Large-Core Arc Tunnel (LCAT). In the LCAT test series, material layups were subjected to aerothermal loads commensurate with peak re-entry conditions enveloping a range of HIAD mission trajectories. The FTPS layups were tested over a heat flux range from 20 to 50 W/cm with associated surface pressures of 3 to 8 kPa. To support the testing effort a significant redesign of the existing shear (wedge) model holder from previous testing efforts was undertaken to develop a new test technique for supporting and evaluating the FTPS in the high-temperature, arc jet flow. Since the FTPS test samples typically experience a geometry change during testing, computational fluid dynamic (CFD) models of the arc jet flow field and test model were developed to support the testing effort. The CFD results were used to help determine the test conditions experienced by the test samples as the surface geometry changes. This paper includes an overview of the Boeing LCAT facility, the general approach for testing FTPS, CFD analysis methodology and results, model holder design and test methodology, and selected thermal results of several FTPS layups.

Bruce, Walter E., III↗
NASA NTRS1997

Mixing of Supersonic Streams

The Strutjet approach to Rocket Based Combined Cycle (RBCC) propulsion depends upon fuel-rich flows from the rocket nozzles and turbine exhaust products mixing with the ambient air for successful operation in the ramjet and scramjet modes. A model of the Strutjet device has been built and is undergoing test to investigate the mixing of the streams as a function of distance from the Strutjet exit plane. The modeling basis was centered on using convective Mach Number as the similarity parameter to establish correlation between subscale, cold flow tests and full scale, hot firing modes. This parameter has been used successfully to correlate supersonic shear layer growth rates. The experiment design includes hot (600 R) air as the rocket exhaust simulant and hot (760 R) carbon dioxide as the turbine exhaust gas simulant. The combination of gases and their elevated temperatures was required to achieve a convective Mach Number which matched the fall scale item design conditions. The carbon dioxide is seeded with Acetone to permit tracing of the mixing processes through Laser Induced Fluorescence (LIF) techniques. The experiment and its design will be discussed in detail. Both the rocket and turbine exhaust duct nozzles are of unique (square and rectangular) shape and the turbine exhaust e)dt intersects the rocket nozzle wall upstream of the exit. Cold flow testing with the individual nozzles has been conducted to ascertain their behavior in comparison to conventional flow theory. These data are presented.

Hawk, Clark W.↗
DOE OSTI2023

Development of an Advanced Hydrogen Energy Storage System using Aerogel in a Cryogenic Flux Capacitor

The Cryogenic Flux Capacitor (CFC) is a cold, dense fluid storage core with integrated design features that afford the designer flexibility and provide new possibilities for the storage and discharge of energy. The stored energy, in this case, is represented by hydrogen physically bonded within the nanoscale pores within the aerogel composite blanket material, and the process of bonding or debonding is governed by the principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m 2 /g) allows for storage densities close to, or in some cases exceeding, that of normal boiling point liquids. Its performance easily exceeds what can be achieved via ambient temperature and high-pressure gas storage for an equivalent volume. CFC storage is predicted to be easily scalable, constructed from readily available commercial materials, and lends itself to a range of pressure applications. The project team designed and manufactured the CFC, integrating it into a set of temperature-controlled flow loops. The CFC test setup was validated against existing data from previous NASA work. Tests used bottled hydrogen gas for test validation. A cryogenic fluid, nitrogen, flowed through a metered control system. Hydrogen temperature, pressure, and flow rates, as well as the temperature control targets, provided all necessary control targets. The team analyzed the recorded data and updated the Technology Maturation Plan based on the results of the test, making recommendations for a follow-up test, scale-up, and maturation pathway. For the engineering development and maturation of CFC hydrogen storage technology, a Techno-Economic Assessment (TEA) and Commercialization Plan for the integration of this technology with various power generation assets were produced. A companion analytical model was developed, experimentally validated, compared against performance metric, and used to tune the model and scale up the technology.

08 HYDROGEN↗
NASA NTRS1981

Crossflow effects on steady and fluctuating pressures on an ogive-cylinder cone-frustum model in supersonic separated flow

Wind-tunnel tests were conducted on an ogive-cylinder model with two axisymmetric protuberances having cone frustum angles of cone = 23 deg and 45 deg that were used to generate detached shock waves and the resulting separated flow areas downstream of the shock. The tests were conducted in a 9 by 7 foot supersonic wind tunnel at a free-stream Mach number of 2.0 and at Reynolds numbers of 1.5 x 1 million and 3.9 x 1 million, based on body diameter. The model had an afterbody fineness ratio of 8.3, and the ogive nose had a fineness ratio of 3.0. Two characteristics of the fluctuating pressures in surface vortex flows that result from the crossflow component, (velocity along the tunnel longitudinal axis free stream angle of attack), in combination with changes in the longitudinal pressure gradient were measured: (1) the broadband, rms-pressure coefficients and (2) the power spectral densities. Measurements are presented for various flow regions on the model such as the attached turbulent boundary layer, the detached frustum shock wave, and separated flow areas. The results indicate that the pressure fluctuations around or in the neighborhood of the foci of the vortex flows had broadband intensities and power spectral densities nearly identical to the levels previously measured in separated-flow regions at angles of attack of 0 deg.

Dods, J. B., Jr.↗
DOE OSTI2026

Reactive Transport Modeling with Physics-Informed Machine Learning for Critical Minerals Applications

This study presents a physics-informed neural network (PINN) framework for reactive transport modeling for simulating fast bimolecular reactions in porous media. Accurate characterization of cAhemical interactions and product formation in surface and subsurface environments is essential for advancing critical mineral extraction and related geoscience applications. The proposed methodology sequentially addresses the flow and diffusion–reaction subproblems. The flow field is computed using a mixed formulation, while the diffusion–reaction system is modeled via two uncoupled tensorial diffusion equations reformulated in terms of chemical invariants. PINNs are employed to solve the governing equations, enabling data-efficient, mesh-free prediction of chemical concentration fields. The framework is validated through a series of benchmark problems involving flow in heterogeneous porous media. Initial verification is conducted using patch tests for the flow field, followed by validation of the transport problem with emphasis on preserving non-negativity of concentrations. The complete fast bimolecular reaction scenario is then solved, yielding spatial distributions of reactants and product species. Results demonstrate that the PINNs-based approach effectively captures sharp, mixing-limited reaction fronts and dispersive mixing behavior, offering reliable predictions of reactive plume evolution. These capabilities are crucial for evaluating long-term subsurface behavior in applications such as fluid storage, energy extraction, and efficient extraction of critical minerals.

42 ENGINEERING↗
DOE OSTI2023

A universal velocity transformation for boundary layers with pressure gradients

The logarithmic law of the wall does not capture the mean flow when a boundary layer is subjected to a strong pressure gradient. In such a boundary layer, the mean flow is affected by the spatio-temporal history of the imposed pressure gradient; and accounting for history effects remains a challenge. This work aims to develop a universal mean flow scaling for boundary layers subjected to arbitrary adverse or/and favourable pressure gradients. Here, we derive from the Navier–Stokes equation a velocity transformation that accounts for the history effects and maps the mean flow to the canonical law of the wall. The transformation is tested against channel flows with a suddenly imposed adverse or favourable pressure gradient, boundary layer flows subjected to an adverse pressure gradient, and Couette–Poiseuille flows with a streamwise pressure gradient. It is found that the transformed velocity profiles follow closely the equilibrium law of the wall.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1988

Shuttle RCS primary thruster injector flow visualization

An image-transmitting fiber-optics scope with a dry gas purge of the optics head has been used to visually evaluate the condition of surplus thrusters in the Space Shuttle's Reaction Control System; it was subsequently applied to flight thrusters. The technique uses water for flow visualization, and obviates thruster disassembly. The innovative use of gas purging of a fiber-optics head allows the unobstructed and distortion-free viewing of the flow streams, and testing has shown the technique to be ideally suited to injector flow assessments following thruster exposure to extensive contamination.

Wells, Dennis L.↗
NASA NTRS1991

Least-squares/parabolized Navier-Stokes procedure for optimizing hypersonic wind tunnel nozzles

A new procedure is demonstrated for optimizing hypersonic wind-tunnel-nozzle contours. The procedure couples a CFD computer code to an optimization algorithm, and is applied to both conical and contoured hypersonic nozzles for the purpose of determining an optimal set of parameters to describe the surface geometry. A design-objective function is specified based on the deviation from the desired test-section flow-field conditions. The objective function is minimized by optimizing the parameters used to describe the nozzle contour based on the solution to a nonlinear least-squares problem. The effect of the changes in the nozzle wall parameters are evaluated by computing the nozzle flow using the parabolized Navier-Stokes equations. The advantage of the new procedure is that it directly takes into account the displacement effect of the boundary layer on the wall contour. The new procedure provides a method for optimizing hypersonic nozzles of high Mach numbers which have been designed by classical procedures, but are shown to produce poor flow quality due to the large boundary layers present in the test section. The procedure is demonstrated by finding the optimum design parameters for a Mach 10 conical nozzle and a Mach 6 and a Mach 15 contoured nozzle.

Korte, John J.↗
NASA NTRS1994

Advances in LO2 Propellant Conditioning

This paper describes the cryogenic testing and analysis that has recently been completed as part of a multi-year effort to develop a new, more robust and operable LO2 propellant conditioning system. Phase 1 of the program consisted of feasibility demonstrations ot four novel propellant conditioning concepts. A no-bleed, passive propellant conditioning option was shown for the first time to successfully provide desired propellant inlet conditions. The benefits of passive conditioning are reduced operations costs, decreased hardware costs, enhanced operability and increased reliability on future expendable launch vehicles In Phase 2 of the test program, effects of major design parameters were studied and design correlation for future vehicle design were developed. Simultaneously, analytical models were developed and validated. Over 100 tests were conducted with a full-scale feedline using LN2 as the test fluid. A circulation pump provided a range of pressure and flow conditions. The test results showed that the passive propellant conditioning system is insensitive to variations in many of the parameters. The test program provides the validation necessary to incorporate the passive conditioning system into the baseline of future vehicles. Modeling of these systems using computational fluid dynamics seems highly promising.

Mehta, Gopal↗
NASA NTRS2020

Maxar Electric Propulsion Development for Deep Space

Maxar has completed development activity for its deep-space electric propulsion system in support of NASA’s Psyche mission. Psyche’s electric propulsion system relies heavily on Maxar’s heritage EP-140 subsystem centered on the SPT-140. The evolution to the EP-140DS demonstrates an expanded thruster discharge capability from 0.9kW through 4.5kW and includes the addition of a constant keeper current function. This system, with development support from industry experts at JPL, will serve as the primary propulsion on board the Psyche spacecraft through the 3.6 year cruise to the Psyche asteroid. Subsystem level testing to validate the first EP-140DS design is complete. Major findings from system testing including xenon flow control loop timing, noise hardening, and constant keeper current and test activities are now being implemented in hardware and the status and plans are discussed.

Chaplin, Vernon↗
NASA NTRS1976

Langley facility for tests at Mach 7 of subscale, hydrogen-burning, airframe-integratable, scramjet models

Modifications to a 20-megawatt arc-heated facility for testing a hydrogen-burning, airframe-integratable, subscale, scramjet model are described. Arc-heated flow is mixed with unheated air to furnish a test flow duplicating Mach 7 flight. (Stagnation temperature is 2220 K.) Modifications to the commercially available heater to improve survivability and smoothness are described. Pitot profiles show uniform flow and a slightly thinner nozzle boundary layer than predicted. Comparison of the tunnel boundary layer, which will be ingested by the engine model, with the boundary layer that a flight engine might ingest from its vehicle forebody shows a difference in the density distribution through the boundary layer. Calculations of wall heating and transient wall temperatures of the engine model show that for a 30-sec burn, the heat sink model requires cooling at selected locations to avoid thermal-stress, cycle-life problems. Model performance predictions show that fuel equivalence ratio and nozzle exit area both have large effects on thrust. Average inlet entrance Mach number (as affected by boundary-layer ingestion) has little effect on thrust.

Boatright, W. B.↗
NASA NTRS1972

Experimental and Analytical Investigation of the Coolant Flow Characteristics in Cooled Turbine Airfoils

The flow characteristics of turbine airfoil cooling system components were experimentally investigated. Flow models representative of leading edge impingement, impingement with crossflow (midchord cooling), pin fins, feeder supply tube, and a composite model of a complete airfoil flow system were tested. Test conditions were set by varying pressure level to cover the Mach number and Reynolds number range of interest in advanced turbine applications. Selected geometrical variations were studied on each component model to determine these effects. Results of these tests were correlated and compared with data available in the literature. Orifice flow was correlated in terms of discharge coefficients. For the leading edge model this was found to be a weak function of hole Mach number and orifice-to-impinged wall spacing. In the impingement with crossflow tests, the discharge coefficient was found to be constant and thus independent of orifice Mach number, Reynolds number, crossflow rate, and impingement geometry. Crossflow channel pressure drop showed reasonable agreement with a simple one-dimensional momentum balance. Feeder tube orifice discharge coefficients correlated as a function of orifice Mach number and the ratio of the orifice-to-approach velocity heads. Pin fin data was correlated in terms of equivalent friction factor, which was found to be a function of Reynolds number and pin spacing but independent of pin height in the range tested.

Damerow, W. P.↗
NASA NTRS1999

Rotor Re-Design for the SSME Fuel Flowmeter

The present report describes the process of redesigning a new rotor for the SSME Fuel Flowmeter. The new design addresses the specific requirement of a lower rotor speed which would allow the SSME operation at 1 15% rated power level without reaching a blade excitation by the wakes behind the hexagonal flow straightener upstream at frequencies close to the blade natural frequency. A series of calculations combining fleet flowmeters test data, airfoil fluid dynamics and CFD simulations of flow patterns behind the flowmeter's hexagonal straightener has led to a blade twist design alpha = alpha (radius) targeting a kf constant of 0.8256. The kf constant relates the fuel volume flow to the flowmeter rotor speed, for this particular value 17685 GPM at 3650 RPM. Based on this angle distribution, two actual blade designs were developed. A first design using the same blade airfoil as the original design targeted the new kf value only. A second design using a variable blade chord length and airfoil relative thickness targeted simultaneously the new kf value and an optimum blade design destined to provide smooth and stable operation and a significant increase in the blade natural frequency associated with the first bending mode, such that a comfortable margin could be obtained at 115% RPL. The second design is a result of a concurrent engineering process, during which several iterations were made in order to achieve a targeted blade natural frequency associated with the first bending mode of 1300 Hz. Water flow tests preliminary results indicate a kf value of 0.8179 for the f-irst design, which is within 1% of the target value. The second design rotor shows a natural frequency associated with the first bending mode of 1308 Hz, and a water-flow calibration constant of kf 0.8169.

Marcu, Bogdan↗
NASA NTRS1991

Flow Visualization Study of a 1/48-Scale AFTI/F111 Model to Investigate Horizontal Tail Flow Disturbances

During flight testing of the AFTI/F111 aircraft, horizontal tail buffet was observed. Flutter analysis ruled out any aeroelastic instability, so a water-tunnel flow visualization study was conducted to investigate possible flow disturbances on the horizontal tail which might cause buffet. For this study, a 1/48-scale model was used. Four different wing cambers and one horizontal tail setting were tested between 0 and 20 deg angle of attack. These wing cambers corresponded to the following leading training edge deflections: 0/2, 10/10, 10/2, and 0/10. Flow visualization results in the form of still photographs are presented for each of the four wing cambers between 8 and 12 deg angle of attack. In general, the horizontal tail experiences flow disturbances which become more pronounced with angle of attack or wing trailing-edge deflection.

Bjarke, Lisa J.↗
NASA NTRSDate not supplied

Reference-Free, Projection Background-Oriented Schlieren

A projection background-oriented schlieren (P-BOS) system is developed and demonstrated. Instead of a background that has a speckle pattern printed, painted, or otherwise deposited onto its surface, and can thus not be altered, the pattern here is projected onto the background. This allows for changes to the speckle pattern without replacement of the background material, which can be time-consuming and expensive. Reference images are acquired simultaneously with flow images. A pre-test transformation between the reference and flow images allows for on-the-fly changes to the speckle pattern during a test without requiring a stoppage of the flow, allowing for optimization of the BOS signal. Using a programmable LCD screen as the speckled optic allows for remote control of the speckle pattern. Because the background is not speckled, the system can be easily transformed to acquired shadowgraph images by removing the speckled optic and closing the aperture of the light source, which is useful for achieving measurements with higher spatial resolution. The system can be nearly as compact as a conventional BOS system, and can be assembled with polarized optics to reduce or eliminate window reflections and glare, making this system particularly well-suited for wind tunnel testing.

Joshua M Weisberger↗
NASA NTRS1990

Airflow Model Testing to Determine the Distribution of Hot Gas Flow and O/F Ratio Across the Space Shuttle Main Engine Main Injector Assembly

Engine 0209, the certification engine for the new Phase 2+ Hot Gas Manifold (HGM), showed severe deterioration of the Main Combustion Chamber (MCC) liner during hot fire tests. One theory on the cause of the damage held that uneven local distribution of the fuel rich hot gas flow through the main injector assembly was producing regions of high oxidizer/fuel (O/F) ratio near the wall of the MCC liner. Airflow testing was proposed to measure the local hot gas flow rates through individual injector elements. The airflow tests were conducted using full scale, geometrically correct models of both the current Phase 2 and the new Phase 2+ HGMs. Different main injector flow shield configurations were tested for each HGM to ascertain their effect on the pressure levels and distribution of hot gas flow. Instrumentation located on the primary faceplate of the main injector measured hot gas flow through selected injector elements. These data were combined with information from the current space shuttle main engine (SSME) power balances to produce maps of pressure, hot gas flow rate, and O/F ratio near the main injector primary plate. The O/F distributions were compared for the different injector and HGM configurations.

Mahorter, L.↗
NASA NTRS2009

Liquid Oxygen/Liquid Methane Test Results of the RS-18 Lunar Ascent Engine at Simulated Altitude Conditions at NASA White Sands Test Facility

Tests were conducted with the RS-18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA's Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to ~122,000 ft (~37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. LO2 flow ranged from 5.9 - 9.5 lbm/sec (2.7 - 4.3 kg/sec), and LCH4 flow varied from 3.0 - 4.4 lbm/sec (1.4 - 2.0 kg/sec) during the RS-18 hot-fire test series. Propellant flow rate was measured using a coriolis mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup due to two-phase flow effects. Subsequent cold-flow testing demonstrated that the propellant manifolds must be adequately flushed in order for the coriolis flow meters to give accurate data. The coriolis flow meters were later shown to provide accurate steady-state data, but the turbine flow meter data should be used in transient phases of operation. Thrust was measured using three load cells in parallel, which also provides the capability to calculate thrust vector alignment. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes. All of these objectives were met with the RS-18 data and additional testing data from subsequent LO2/methane test programs in 2009 which included the first simulated-altitude pyrotechnic ignition demonstration of LO2/methane.

Melcher, John C., IV↗