Results for “Engine Ground Testing” — Page 9

NASA NTRS2007

The Effect of Acoustic Disturbances on the Operation of the Space Shuttle Main Engine Fuel Flowmeter

The Space Shuttle Main Engine (SSME) uses a turbine fuel flowmeter (FFM) in its Low Pressure Fuel Duct (LPFD) to measure liquid hydrogen flowrates during engine operation. The flowmeter is required to provide accurate and robust measurements of flow rates ranging from 10000 to 18000 GPM in an environment contaminated by duct vibration and duct internal acoustic disturbances. Errors exceeding 0.5% can have a significant impact on engine operation and mission completion. The accuracy of each sensor is monitored during hot-fire engine tests on the ground. Flow meters which do not meet requirements are not flown. Among other parameters, the device is screened for a specific behavior in which a small shift in the flow rate reading is registered during a period in which the actual fuel flow as measured by a facility meter does not change. Such behavior has been observed over the years for specific builds of the FFM and must be avoided or limited in magnitude in flight. Various analyses of the recorded data have been made prior to this report in an effort to understand the cause of the phenomenon; however, no conclusive cause for the shift in the instrument behavior has been found. The present report proposes an explanation of the phenomenon based on interactions between acoustic pressure disturbances in the duct and the wakes produced by the FFM flow straightener. Physical insight into the effects of acoustic plane wave disturbances was obtained using a simple analytical model. Based on that model, a series of three-dimensional unsteady viscous flow computational fluid dynamics (CFD) simulations were performed using the MSFC PHANTOM turbomachinery code. The code was customized to allow the FFM rotor speed to change at every time step according to the instantaneous fluid forces on the rotor, that, in turn, are affected by acoustic plane pressure waves propagating through the device. The results of the simulations show the variation in the rotation rate of the flowmeter due to the interaction of the flow straightener wakes and the upstream propagating acoustic waves. A detailed analysis of the acoustic disturbance effects is presented along with an assessment of the impact on measurement accuracy.

Marcu, Bogdan↗

NASA NTRSDate not supplied

Four Bed Carbon Dioxide Scrubber Engineering Development Unit Cabin Air Inlet Testing

This paper reviews a test series conducted on the Four Bed Carbon Dioxide Scrubber Engineering Development Unit, a ground test analog for the Four Bed Carbon Dioxide Scrubber Technology Demonstration currently operating on the International Space Station. For this test series conducted in mid-2022, an alternate FBCO2 inlet air location (direct from the cabin) was evaluated. This paper presents test results, rationale for observed performance changes, and possible ramifications for the flight FBCO2 Scrubber.

Life Support↗

NASA NTRSDate not supplied

Four Bed Carbon Dioxide Scrubber Engineering Development Unit Cabin Air Inlet Testing

This paper reviews a test series conducted on the Four Bed Carbon Dioxide Scrubber Engineering Development Unit, a ground test analog for the Four Bed Carbon Dioxide Scrubber Technology Demonstration currently operating on the International Space Station. For this test series conducted in mid-2022, an alternate FBCO2 inlet air location (direct from the cabin) was evaluated. This paper presents test results, rationale for observed performance changes, and possible ramifications for the flight FBCO2 Scrubber.

Life Support↗

NASA NTRS1966

Thermal Control of Liquid H2/O2 Rocket Engines and Vehicle Impact

Cryogenic propulsion systems are subjected to various engine start environments during ground testing, first burn, and restart after orbital coast. These operational modes necessitate careful engine-stage integration, particularly in thermal control of propellant feed systems and engine subsystems. The wide range of operational conditions imposed on propellant feed systems include varying heat loads and acceleration forces for static test first burn and orbital restart. One method used to provide Net Positive Suctign,Head (NPSH) and maintain turbopump I is thermal control propellant circulation through the feed system prior to engine start. The attendant design and operational criteria are inter-related with stage and vehicle systems, including for example, auxiliary propulsion and propellant ullaging methods such as propellant tank propulsive venting. Thermally sensitive engine components require environmental control, protection, or special sequencing in order to assure repeatable engine start performance. An example is thrust chamber pre-chill to avoid pump stall during rapid start transient. Trends in engine development are toward expanding system flexibility to accommodate the wide variety of environments without special pre-start conditioning.

Winstead, Thomas W.↗

NASA NTRS1983

Development of the Space Shuttle main engine

The history of the development, certification, and launch operations of the Space Shuttle Main Engine is described. Development problems and their solutions are discussed. Ground testing at both rated and full power levels involving four engines and eight certification test cycles totalling more than 40,000 seconds of hot-fire testing, which qualified both Columbia's and Challenger's engines for flight, are discussed. Ground checkout and flight performance of Columbia's and Challenger's engines are revealed. Future plans for the Space Shuttle Main Engine are outlined including flight certification testing to verify a life of 40 flights and 20,000 seconds operation before overhaul.

Klatt, F. P.↗

NASA NTRS2010

The History and Promise of Combined Cycle Engines for Access to Space Applications

For the summer of 2010, I have been working in the Aerodynamics and Propulsion Branch at NASA Dryden Flight Research Center studying combined-cycle engines, a high speed propulsion concept. Combined cycle engines integrate multiple propulsion systems into a single engine capable of running in multiple modes. These different modes allow the engine to be extremely versatile and efficient in varied flight conditions. The two most common types of combined cycle engines are Rocket-Based Combined Cycle (RBCC) and Turbine Based Combined Cycle (TBCC). The RBCC essentially combines a rocket and ramjet engine, while the TBCC integrates a turbojet and ramjet1. These two engines are able to switch between different propulsion modes to achieve maximum performance. Extensive conceptual and ground test studies of RBCC engines have been undertaken; however, an RBCC engine has never, to my knowledge, been demonstrated in flight. RBCC engines are of particular interest because they could potentially power a reusable launch vehicle (RLV) into space. The TBCC has been flight tested and shown to be effective at reaching supersonic speeds, most notably in the SR-71 Blackbird2.

Clark, Casie↗

NASA NTRS2022

Regolith Simulant Preparation and Geotechnical Characterization for Plume Surface Interaction Testing

Descent engine plumes interact with the lunar surface and accelerate regolith particles to potentially high velocities. These ejecta create risks to surface assets that have yet to be fully assessed. To better understand these risks, plume surface interactions can be simulated on the ground by firing a test engine plume into a bin of lunar regolith simulant under vacuum conditions. The dynamics of the resultant ejecta can then be recorded. In this technical memorandum we discuss the processes used in preparing a 150 kg bin of lunar regolith simulant for plume surface interaction ground tests under vacuum conditions for the NASA STMD Plume Surface Interaction project. We present our approach to mitigating regolith simulant eruptions during pump-down, the methods used to fill and reset the regolith simulant bin for each test, and the techniques used to characterize the consistency of regolith simulant geotechnical properties before each new firing. The challenges of preparing a regolith simulant test bin below an ambient pressure of one atmosphere, particularly on the large scale, could largely be overcome with a system that could fill the test bin with simulant inside the chamber and under vacuum conditions.

lunar regolith↗

NASA NTRS1975

NASA refan program status

The objective of the refan program is to demonstrate the technical feasibility of substantially reducing the noise levels of existing JT8D powered aircraft. The program consists of the design, manufacturing and testing of the refan engines and modified nacelles and airplanes. Experimental testing was completed for the refan engine both at sea level and at altitude conditions. Ground testing for the B727 side- and center-engine installations and flight testing of the DC-9 with refan engines and acoustic nacelles were performed. Preliminary results presented show that substantial noise reductions were achieved.

Abdalla, K. L.↗

NASA NTRS1975

NASA refan program status

The objective of the refan program is to demonstrate the technical feasibility of substantially reducing the noise levels of existing JT8D powered aircraft. The program consists of the design, manufacturing and testing of the refan engines and modified nacelles and airplanes. Experimental testing has been completed for the refan engine both at sea level and at altitude conditions. Ground testing for the B727 side- and center-engine installations and flight testing of the DC-9 with refan engines and acoustic nacelles have been performed. Analyses of the test results are in progress. Preliminary results presented in this paper show that substantial noise reductions were achieved.

Abdalla, K. L.↗

NASA NTRS1980

AiResearch QCGAT engine: Acoustic test results

The noise levels of the quiet, general aviation turbofan (QCGAT) engine were measured in ground static noise tests. The static noise levels were found to be markedly lower than the demonstrably quiet AiResearch model TFE731 engine. The measured QCGAT noise levels were correlated with analytical noise source predictions to derive free-field component noise predictions. These component noise sources were used to predict the QCGAT flyover noise levels at FAR Part 36 conditions. The predicted flyover noise levels are about 10 decibels lower than the current quietest business jets.

Kisner, L. S.↗

NASA NTRS2001

Hyper-X Mach 10 Engine Flowpath Development: Fifth Entry Test Conditions and Methodology

A series of Hyper-X Mach 10 flowpath ground tests are underway to obtain engine performance and operation data and to confirm and refine the flowpath design methods. The model used is a full-scale height, partial-width replica of the Hyper-X Research Vehicle propulsive flowpath with truncated forebody and aftbody. This is the fifth test entry for this model in the NASA-HYPULSE facility at GASL. For this entry the facility nozzle and model forebody were modified to better simulate the engine inflow conditions at the target flight conditions. The forebody was modified to be a wide flat plate with no flow fences, the facility nozzle Mach number was increased, and the model was positioned to be tested in a semi-direct-connect arrangement. This paper presents a review of the test conditions, model calibrations, and a description of steady flow confirmation. The test series included runs using hydrogen fuel, and a silane-in-hydrogen fuel mixture. Other test parameters included the model mounting angle (relative to the tunnel flow), and the test gas oxygen fraction to account for the presence of [NO] in the test gas at the M10 conditions.

Bakos, R. J.↗

NASA NTRS2017

Evaluation of the Uncertainty in JP-7 Kinetics Models Applied to Scramjets

One of the challenges of designing and flying a scramjet-powered vehicle is the difficulty of preflight testing. Ground tests at realistic flight conditions introduce several sources of uncertainty to the flow that must be addressed. For example, the scales of the available facilities limit the size of vehicles that can be tested and so performance metrics for larger flight vehicles must be extrapolated from ground tests at smaller scales. To create the correct flow enthalpy for higher Mach number flows, most tunnels use a heater that introduces vitiates into the flow. At these conditions, the effects of the vitiates on the combustion process is of particular interest to the engine designer, where the ground test results must be extrapolated to flight conditions. In this paper, the uncertainty of the cracked JP-7 chemical kinetics used in the modeling of a hydrocarbon-fueled scramjet was investigated. The factors that were identified as contributing to uncertainty in the combustion process were the level of flow vitiation, the uncertainty of the kinetic model coefficients and the variation of flow properties between ground testing and flight. The method employed was to run simulations of small, unit problems and identify which variables were the principal sources of uncertainty for the mixture temperature. Then using this resulting subset of all the variables, the effects of the uncertainty caused by the chemical kinetics on a representative scramjet flow-path for both vitiated (ground) and nonvitiated (flight) flows were investigated. The simulations showed that only a few of the kinetic rate equations contribute to the uncertainty in the unit problem results, and when applied to the representative scramjet flowpath, the resulting temperature variability was on the order of 100 K. Both the vitiated and clean air results showed very similar levels of uncertainty, and the difference between the mean properties were generally within the range of uncertainty predicted.

Norris, A. T.↗

NASA NTRS2018

New Efforts to Update NASA's Global Reference Atmospheric Models (GRAM)

NASA is at the forefront of planetary exploration. The inability to test planetary spacecraft in the flight environment prior to a mission requires engineers to rely on ground-based testing and models of the vehicle and expected environments. One of the most widely used engineering models of the atmosphere for many NASA projects is the Global Reference Atmospheric Model (GRAM) developed by the NASA Marshall Space Flight Center (MSFC). Over the past decade GRAM upgrades and maintenance have depended on inconsistent and waning project-specific support. Recently, the NASA Science Mission Directorate agreed to provide funding support in Fiscal Year 2018 and 2019 to upgrade the GRAMs. This poster summarizes the objectives, tasks and milestones of this effort.

Justh, Hilary↗

NASA NTRS2018

New Efforts to Update NASA's Global Reference Atmospheric Models (GRAM)

NASA is at the forefront of planetary exploration. The inability to test planetary spacecraft in the flight environment prior to a mission requires engineers to rely on ground-based testing and models of the vehicle and expected environments. One of the most widely used engineering models of the atmosphere for many NASA projects is the Global Reference Atmospheric Model (GRAM) developed by the NASA Marshall Space Flight Center (MSFC). Over the past decade GRAM upgrades and maintenance have depended on inconsistent and waning project-specific support. Recently, the NASA Science Mission Directorate agreed to provide funding support in Fiscal Year 2018 and 2019 to upgrade the GRAMs. This poster summarizes the objectives, tasks and milestones of this effort.

Dwyer Cianciolo, Alicia↗

NASA NTRS2019

Mars Global Reference Atmospheric Model (Mars-GRAM) Upgrades

The inability to test planetary spacecraft in the flight environment prior to a mission requires engineers to rely on ground-based testing and models of the vehicle and expected environments. One of the most widely used engineering models of the Martian atmosphere is the Mars Global Reference Atmospheric Model (Mars-GRAM) developed and maintained by the NASA Marshall Space Flight Center (MSFC). The NASA Science Mission Directorate (SMD) has provided funding support to upgrade the planetary GRAMs in Fiscal Year 2018 and 2019. This poster summarizes the upgrades that have been made to Mars-GRAM, the release status of Mars-GRAM, the new GRAMs that are under development, and future Mars-GRAM upgrade plans.

Justh, H. L.↗

NASA NTRS2020

Status of Outer Planet Global Reference Atmospheric Model (GRAM) Upgrades

The inability to test planetary spacecraft in the flight environment prior to a mission requires engineers to rely on ground-based testing and models of the vehicle and expected environments. One of the most widely used engineering models of the atmosphere is the Global Reference Atmospheric Model (GRAM) developed and maintained by the NASA Marshall Space Flight Center (MSFC). The NASA Science Mission Directorate (SMD) has provided funding support to upgrade the GRAMs.

Justh, H. L.↗

NASA NTRSDate not supplied

Venus Global Reference Atmospheric Model (GRAM) Upgrades

The inability to test planetary spacecraft in the flight environment prior to a mission requires engineers to rely on ground-based testing and models of the vehicle and expected environments. One of the most widely used engineering models of Venus’ atmosphere is the Venus Global Reference Atmospheric Model (Venus-GRAM).The Venus-GRAM upgrades are being developed by NASA Marshall Space Flight Center and NASA Langley Research Center.

atmospheric models↗

NASA NTRSDate not supplied

Upgrades to the Mars Global Reference Atmospheric Model (Mars-GRAM)

The inability to test planetary spacecraft in the flight environment prior to a mission requires engineers to rely on ground-based testing and models of the vehicle and expected environments. One of the most widely used engineering reference models of planetary atmospheres are the Global Reference Atmospheric Models (GRAMs). The NASA Science Mission Directorate (SMD) has provided funding support to upgrade the GRAMs since Fiscal Year 2018. The GRAM upgrades are being developed by NASA Marshall Space Flight Center and NASA Langley Research Center. This poster provides details regarding recent MarsGRAM upgrades.

atmospheric models↗