Results for “Combustion system design optimization”

NASA NTRS2001

Overview of the NCC

A multi-disciplinary design/analysis tool for combustion systems is critical for optimizing the low-emission, high-performance combustor design process. Based on discussions between then NASA Lewis Research Center and the jet engine companies, an industry-government team was formed in early 1995 to develop the National Combustion Code (NCC), which is an integrated system of computer codes for the design and analysis of combustion systems. NCC has advanced features that address the need to meet designer's requirements such as "assured accuracy", "fast turnaround", and "acceptable cost". The NCC development team is comprised of Allison Engine Company (Allison), CFD Research Corporation (CFDRC), GE Aircraft Engines (GEAE), NASA Glenn Research Center (LeRC), and Pratt & Whitney (P&W). The "unstructured mesh" capability and "parallel computing" are fundamental features of NCC from its inception. The NCC system is composed of a set of "elements" which includes grid generator, main flow solver, turbulence module, turbulence and chemistry interaction module, chemistry module, spray module, radiation heat transfer module, data visualization module, and a post-processor for evaluating engine performance parameters. Each element may have contributions from several team members. Such a multi-source multi-element system needs to be integrated in a way that facilitates inter-module data communication, flexibility in module selection, and ease of integration. The development of the NCC beta version was essentially completed in June 1998. Technical details of the NCC elements are given in the Reference List. Elements such as the baseline flow solver, turbulence module, and the chemistry module, have been extensively validated; and their parallel performance on large-scale parallel systems has been evaluated and optimized. However the scalar PDF module and the Spray module, as well as their coupling with the baseline flow solver, were developed in a small-scale distributed computing environment. As a result, the validation of the NCC beta version as a whole was quite limited. Current effort has been focused on the validation of the integrated code and the evaluation/optimization of its overall performance on large-scale parallel systems.

Liu, Nan-Suey↗

NASA NTRS1999

NCC: A Multidisciplinary Design/Analysis Tool for Combustion Systems

A multi-disciplinary design/analysis tool for combustion systems is critical for optimizing the low-emission, high-performance combustor design process. Based on discussions between NASA Lewis Research Center and the jet engine companies, an industry-government team was formed in early 1995 to develop the National Combustion Code (NCC), which is an integrated system of computer codes for the design and analysis of combustion systems. NCC has advanced features that address the need to meet designer's requirements such as "assured accuracy", "fast turnaround", and "acceptable cost". The NCC development team is comprised of Allison Engine Company (Allison), CFD Research Corporation (CFDRC), GE Aircraft Engines (GEAE), NASA Lewis Research Center (LeRC), and Pratt & Whitney (P&W). This development team operates under the guidance of the NCC steering committee. The "unstructured mesh" capability and "parallel computing" are fundamental features of NCC from its inception. The NCC system is composed of a set of "elements" which includes grid generator, main flow solver, turbulence module, turbulence and chemistry interaction module, chemistry module, spray module, radiation heat transfer module, data visualization module, and a post-processor for evaluating engine performance parameters. Each element may have contributions from several team members. Such a multi-source multi-element system needs to be integrated in a way that facilitates inter-module data communication, flexibility in module selection, and ease of integration.

Liu, Nan-Suey↗

NASA NTRS1980

NASA broadened-specification fuels combustion technology program

The broadened-Specification Fuels Combustion Technology program's purpose is to evolve and demonstrate the technology required to enable current and next generation high-thrust, high-bypass-ratio turbofan engines to use fuels with broadened properties and to verify the evolved technology in full scale engine tests. The three phases of the program are combustor concept screening, combustor optimization testing, and engine verification testing. Constraints for designing combustion systems are outlined and problems to be expected in the use of broadened properties fuels are listed.

Fear, J. S.↗

NASA NTRS1998

Summer Work Experience: Determining Methane Combustion Mechanisms and Sub-Scale Diffuser Properties for Space Transporation System Engine Testing

To assess engine performance during the testing of Space Shuttle Main Engines (SSMEs), the design of an optimal altitude diffuser is studied for future Space Transportation Systems (STS). For other Space Transportation Systems, rocket propellant using kerosene is also studied. Methane and dodecane have similar reaction schemes as kerosene, and are used to simulate kerosene combustion processes at various temperatures. The equations for the methane combustion mechanism at high temperature are given, and engine combustion is simulated on the General Aerodynamic Simulation Program (GASP). The successful design of an altitude diffuser depends on the study of a sub-scaled diffuser model tested through two-dimensional (2-D) flow-techniques. Subroutines given calculate the static temperature and pressure at each Mach number within the diffuser flow. Implementing these subroutines into program code for the properties of 2-D compressible fluid flow determines all fluid characteristics, and will be used in the development of an optimal diffuser design.

Williams, Powtawche N.↗

NASA NTRSDate not supplied

Pretest Simulations of a Supersonic Mixing and Combustion Validation Experiment to Assess Sensitivities

The reliance on CFD simulations to develop, design, and optimize scramjet systems (or components) has become commonplace. This reliance inevitably hinges on the ability of the computational analyst to quantify the level of confidence in their computational results. Unfortunately, nearly all the measured data available for this assessment comes from antiquated experimental datasets, or from tests that focused on the extraction of scramjet system (or component) performance. The objective of a CFD validation experiment is to quantify the predictive accuracy of one or more of the CFD physics submodels, implying that other uncertainties related to replicating the facility flow environment (e.g., knowledge of boundary conditions) must be minimized to the extent possible. This inevitably places stringent requirements on the quality and quantity of measurements taken to accurately specify inflow, outflow, and surface conditions for the CFD simulations; in addition to the measurements taken for the validation of physics submodels. This places additional demands on the experimental process above and beyond those for test article performance assessment. A recent high speed code credibility workshop series sponsored by AFRL identified a gap in existing validation data for fundamental assessments of turbulent mixing and combustion CFD closure models at scramjet engine relevant conditions. To address this gap, engineers at AFRL have designed a coaxial jet flame configuration that will be tested at two facilities (Research Cell 19 at the Air Force Research Lab, and at Purdue University). The effort described here documents pretest simulations of this validation experiment with the goal of fleshing out the extent of the facility flowpath that must be included to adequately reproduce the facility test section flow environment. The findings indicate that the flow around the support structure for the fuel injection centerbody upstream of the facility nozzle generates disturbances that persist throughout the nozzle expansion process; corrupting the azimuthal symmetry that was desired in the fuel/air mixing region of the test section. Simulations without this support structure maintained a high degree of azimuthal symmetry up until the fuel injection plane. However, even in this scenario the azimuthal symmetry was not maintained once the centerbody boundary layer transitioned to a wake flow downstream of the fuel injection plane.

CFD↗

NASA NTRSDate not supplied

Pretest Simulations of a Supersonic Mixing and Combustion Validation Experiment to Assess Sensitivities

The reliance on CFD simulations to develop, design, and optimize scramjet systems (or components) has become commonplace. This reliance inevitably hinges on the ability of the computational analyst to quantify the level of confidence in their computational results. Unfortunately, nearly all the measured data available for this assessment comes from antiquated experimental datasets, or from tests that focused on the extraction of scramjet system (or component) performance. The objective of a CFD validation experiment is to quantify the predictive accuracy of one or more of the CFD physics submodels, implying that other uncertainties related to replicating the facility flow environment (e.g., knowledge of boundary conditions) must be minimized to the extent possible. This inevitably places stringent requirements on the quality and quantity of measurements taken to accurately specify inflow, outflow, and surface conditions for the CFD simulations; in addition to the measurements taken for the validation of physics submodels. This places additional demands on the experimental process above and beyond those for test article performance assessment. A recent high speed code credibility workshop series sponsored by AFRL identified a gap in existing validation data for fundamental assessments of turbulent mixing and combustion CFD closure models at scramjet engine relevant conditions. To address this gap, engineers at AFRL have designed a coaxial jet flame configuration that will be tested at two facilities (Research Cell 19 at the Air Force Research Lab, and at Purdue University). The effort described here documents pretest simulations of this validation experiment with the goal of fleshing out the extent of the facility flowpath that must be included to adequately reproduce the facility test section flow environment. The findings indicate that the flow around the support structure for the fuel injection centerbody upstream of the facility nozzle generates disturbances that persist throughout the nozzle expansion process; corrupting the azimuthal symmetry that was desired in the fuel/air mixing region of the test section. Simulations without this support structure maintained a high degree of azimuthal symmetry up until the fuel injection plane. However, even in this scenario the azimuthal symmetry was not maintained once the centerbody boundary layer transitioned to a wake flow downstream of the fuel injection plane.

CFD↗

NASA NTRS1979

NASA broad-specification fuels combustion technology program: Status and description

The program presented is a contracted effort to evolve and demonstrate the technology required to utilize broad-specification fuels in current and next generation commercial Conventional Takeoff and Landing aircraft engines, and to verify this technology in full-scale engine tests in 1983. The program consists of three phases: Combustor Concept Screening, Combustor Optimization Testing, and Engine Verification Testing. The development and screening of the combustion system designs for the CF6-80 engine and the JT9D-7 engine, respectively, in high-pressure sector test rigs are reported.

Fear, J. S.↗

NASA NTRS1992

Application of Taguchi methods to dual mixture ratio propulsion system optimization for SSTO vehicles

The application of advanced technologies to future launch vehicle designs would allow the introduction of a rocket-powered, single-stage-to-orbit (SSTO) launch system early in the next century. For a selected SSTO concept, a dual mixture ratio, staged combustion cycle engine that employs a number of innovative technologies was selected as the baseline propulsion system. A series of parametric trade studies are presented to optimize both a dual mixture ratio engine and a single mixture ratio engine of similar design and technology level. The effect of varying lift-off thrust-to-weight ratio, engine mode transition Mach number, mixture ratios, area ratios, and chamber pressure values on overall vehicle weight is examined. The sensitivity of the advanced SSTO vehicle to variations in each of these parameters is presented, taking into account the interaction of each of the parameters with each other. This parametric optimization and sensitivity study employs a Taguchi design method. The Taguchi method is an efficient approach for determining near-optimum design parameters using orthogonal matrices from design of experiments (DOE) theory. Using orthogonal matrices significantly reduces the number of experimental configurations to be studied. The effectiveness and limitations of the Taguchi method for propulsion/vehicle optimization studies as compared to traditional single-variable parametric trade studies is also discussed.

Stanley, Douglas O.↗

NASA NTRS1979

Phase 1 of the near team hybrid passenger vehicle development program. Appendix C: Preliminary design data package, volume 1

The methodology used for vehicle layout and component definition is described as well as techniques for system optimization and energy evaluation. The preliminary design is examined with particular attention given to body and structure; propulsion system; crash analysis and handling; internal combustion engine; DC motor separately excited; Ni-Zn battery; transmission; control system; vehicle auxiliarries; weight breakdown, and life cycle costs. Formulas are given for the quantification of energy consumption and results are compared with the reference vehicle.

Piccolo, R.↗

NASA NTRS1985

Fundamental Studies of Droplet Combustion at Reduced Gravity

Reduced gravity is used to carry out scientific investigations of droplet combustion. In earlier work a preliminary conceptual design had been developed for droplet burning experiments for Spacelab. Refinements of the earlier work with special consideration given to possible experiments for Mid-Deck Modules of the Space Shuttle is discussed. A re-evaluation of suitable experiments on droplet combustion is done to ascertain whether influences of reduced buoyancy on time-dependent processes of heat and mass transfer in the gas or in the liquid on extinction processes or on disruptive burning phenomena are best suited for further investigation. Components of the experimental apparatus, which include a droplet dispensing system, a droplet positioning system, a droplet ignition system and provision for recording, primarily photographically, the combustion of the individual droplet in a chamber having a controlled gas atmosphere, are studied to determine optimal approaches to the experimental design. Methods for data reduction and interpretation are being made more specific, particularly in the context of an objective to calculate overall gas-phase chemical-kinetic parameters for the combustion from observations of extinction conditions in different atmospheres.

Williams, F. A.↗

NASA NTRS2012

Development and Testing of a Green-Propellant Micro-Hybrid Thruster with Electrostatic Ignition

As early as 1937 German scientists at Peenemunde experimented with highly unstable fuel blends of nitrous oxide (N2O) and ethanol. These early tests mostly resulted in explosions and destroyed rocket engines. More recently several companies have developed experimental nitrous oxide fuel blends (NOFB) with Isp exceeding 300 sec. Although NOFBx has recently been cleared for tests on the International Space Station, this propellant remains highly experimental and has not been cleared for commercial transport by the US DOT. Recent work by Karabeyoglu et al. has raised concerns about the safety risks of mixing hydrocarbons with N2O. Liquid oxidizer/fuel blends are highly explosive and require extreme care in transport and servicing. By adding small amounts of a liquid organic fuel such as alcohol or a hydrocarbon, the odds of an explosive decomposition event are significantly increased.iv The proposed solution mitigates the explosion hazards of NOFB by separating the oxidizer from the hydrocarbon fuel formed as of a small cylindrical section of ABS thermoplastic. As N2O vapor flows across the grain segment, current enters a 1000 VDC high-tension lead in the ABS fuel grain and produces an inductive spark that vaporizes a small amount of the material. The ablated fuel vapor plus residual energy from the spark seed a localized exothermic N2O dissociation that produces sufficient heat to initiate combustion. The process is also effective when gaseous oxygen is used. A low TRL (2-3) prototype demonstrating the feasibility of controlled hydrocarbon-seeding was recently tested at Utah State University.v The unit features a miniature 2.5 cm ABS fuel grain fabricated using a Stratasys Dimension 3-D printer. The 9-N thruster was pulse-fired up to 27 consecutive times on a single ABS grain segment. Ignition was achieved by as little as 12-15 Joules energy input. This value is contrasted with the typical 30-minute pre-heat requirement for the ECAPS LMP-103S ADN-based monopropellant, requiring an energy input of 14,850 Joules for catalytic dissociation. The hydrocarbon-seeded micro-hybrid was also adapted as a non-pyrotechnic ignitor for a 900 N (200-lbf) thrust hybrid motor. The motor was successfully ignited 4 consecutive times with no hardware swaps or propellant additions. The amount of ABS seed material that can be fit into the injector cap is the only limit to the number of available repeat firings. This series of tests marks the first time a hybrid motor was ever ignited by other than a solid-propellant pyrotechnic charge or bi-propellant flame ignitor. Nitrous oxide hybrid motors are typically difficult to ignite and usually require multiple solid-propellant charges to initiate combustion, so this nonpyrotechnic ignition is a significant accomplishment. The controlled hydrocarbon-seeding approach is fundamentally different from all other green propellant solutions offered by the aerospace industry. Although the proposed system is more correctly a hybrid technology; the system retains all the simple features of a monopropellant design. To date no optimization study has been performed to identify the best grain geometry for electrostatic ignition. Fortunately, because the grain segments are fabricated using rapid-prototyping technology, changing the grain geometry is as simple as modifying the 3-D printer CAD-file. Vacuum Isp exceeding 270 seconds has been demonstrated (Ref v), a value significantly higher than those offered by competing green monopropellant options. The propellants of choice, N2O/GOX and ABS are 100% non-toxic, non-explosive, and environmentally benign. Because the inert oxidizer and fuel components are mixed only within the combustion chamber, the system retains the inherent safety of a hybrid rocket and can be piggy-backed as a secondary payload with no overall mission risk increase to the primary payload, an excellent characteristic for secondary launch systems.

Whitmore, Stephen A.↗

NASA NTRS1976

Numerical optimization of gasdynamic lasers

A sophisticated numerical optimization procedure has been coupled to a detailed theoretical model of the carbon dioxide gasdynamic laser (GDL) for the purpose of systematically evaluating the performance of these systems. The integrated model was used to predict the performance of a wide variety of combustion-driven gasdynamic lasers and was then used to maximize the theoretical available specific energy of these lasers. Up to six design variables and three nonlinear constraints were used in these optimizations, although the method is not limited to this number. Results are presented to show the performance of typical lasers before and after optimization. Improvements approaching a factor of two in the available specific energy are found, suggesting that numerical optimization techniques are valuable in improving the design of gasdynamic lasers.

Saunders, R. C., III↗

NASA NTRS2011

Frame-Transfer Gating Raman Spectroscopy for Time-Resolved Multiscalar Combustion Diagnostics

Accurate experimental measurement of spatially and temporally resolved variations in chemical composition (species concentrations) and temperature in turbulent flames is vital for characterizing the complex phenomena occurring in most practical combustion systems. These diagnostic measurements are called multiscalar because they are capable of acquiring multiple scalar quantities simultaneously. Multiscalar diagnostics also play a critical role in the area of computational code validation. In order to improve the design of combustion devices, computational codes for modeling turbulent combustion are often used to speed up and optimize the development process. The experimental validation of these codes is a critical step in accepting their predictions for engine performance in the absence of cost-prohibitive testing. One of the most critical aspects of setting up a time-resolved stimulated Raman scattering (SRS) diagnostic system is the temporal optical gating scheme. A short optical gate is necessary in order for weak SRS signals to be detected with a good signal- to-noise ratio (SNR) in the presence of strong background optical emissions. This time-synchronized optical gating is a classical problem even to other spectroscopic techniques such as laser-induced fluorescence (LIF) or laser-induced breakdown spectroscopy (LIBS). Traditionally, experimenters have had basically two options for gating: (1) an electronic means of gating using an image intensifier before the charge-coupled-device (CCD), or (2) a mechanical optical shutter (a rotary chopper/mechanical shutter combination). A new diagnostic technology has been developed at the NASA Glenn Research Center that utilizes a frame-transfer CCD sensor, in conjunction with a pulsed laser and multiplex optical fiber collection, to realize time-resolved Raman spectroscopy of turbulent flames that is free from optical background noise (interference). The technology permits not only shorter temporal optical gating (down to <1 s, in principle), but also higher optical throughput, thus resulting in a substantial increase in measurement SNR.

Nguyen, Quang-Viet↗

NASA NTRS2019

Flat-H Redundant Frangible Joint Design Evolution 2018: Feasibility Study Conclusions

This paper reports results of an investigation into developing a single failure tolerant pyrotechnic linear separation system which features completely redundant explosive trains suitable for human spaceflight. It is a follow up to “Flat-H Redundant Frangible Joint Design Evolution 2017” and “Flat-H Redundant Frangible Joint Evolution”. The paper chronicles the history of the redundant frangible joint development program including testing, analysis, and design improvements from 2014 to the present culminating in a successful proof-of-concept prototype. The paper describes work done to address debris control and containment of combustion products. A performance optimization strategy is presented along with optimization results. Additionally a novel containment manifold design is presented with test results.

Structures↗

NASA NTRS1997

National Combustion Code: A Multidisciplinary Combustor Design System

The Internal Fluid Mechanics Division conducts both basic research and technology, and system technology research for aerospace propulsion systems components. The research within the division, which is both computational and experimental, is aimed at improving fundamental understanding of flow physics in inlets, ducts, nozzles, turbomachinery, and combustors. This article and the following three articles highlight some of the work accomplished in 1996. A multidisciplinary combustor design system is critical for optimizing the combustor design process. Such a system should include sophisticated computer-aided design (CAD) tools for geometry creation, advanced mesh generators for creating solid model representations, a common framework for fluid flow and structural analyses, modern postprocessing tools, and parallel processing. The goal of the present effort is to develop some of the enabling technologies and to demonstrate their overall performance in an integrated system called the National Combustion Code.

Stubbs, Robert M.↗

NASA NTRS1998

Design of Life Extending Controls Using Nonlinear Parameter Optimization

This report presents the conceptual development of a life extending control system where the objective is to achieve high performance and structural durability of the plant. A life extending controller is designed for a reusable rocket engine via damage mitigation in both the fuel and oxidizer turbines while achieving high performance for transient responses of the combustion chamber pressure and the O2/H2 mixture ratio. This design approach makes use of a combination of linear and nonlinear controller synthesis techniques and also allows adaptation of the life extending controller module to augment a conventional performance controller of a rocket engine. The nonlinear aspect of the design is achieved using nonlinear parameter optimization of a prescribed control structure.

Lorenzo, Carl F.↗

NASA NTRS2001

Hydrogen/Air Fuel Nozzle Emissions Experiments

The use of hydrogen combustion for aircraft gas turbine engines provides significant opportunities to reduce harmful exhaust emissions. Hydrogen has many advantages (no CO2 production, high reaction rates, high heating value, and future availability), along with some disadvantages (high current cost of production and storage, high volume per BTU, and an unknown safety profile when in wide use). One of the primary reasons for switching to hydrogen is the elimination of CO2 emissions. Also, with hydrogen, design challenges such as fuel coking in the fuel nozzle and particulate emissions are no longer an issue. However, because it takes place at high temperatures, hydrogen-air combustion can still produce significant levels of NOx emissions. Much of the current research into conventional hydrocarbon-fueled aircraft gas turbine combustors is focused on NOx reduction methods. The Zero CO2 Emission Technology (ZCET) hydrogen combustion project will focus on meeting the Office of Aerospace Technology goal 2 within pillar one for Global Civil Aviation reducing the emissions of future aircraft by a factor of 3 within 10 years and by a factor of 5 within 25 years. Recent advances in hydrocarbon-based gas turbine combustion components have expanded the horizons for fuel nozzle development. Both new fluid designs and manufacturing technologies have led to the development of fuel nozzles that significantly reduce aircraft emissions. The goal of the ZCET program is to mesh the current technology of Lean Direct Injection and rocket injectors to provide quick mixing, low emissions, and high-performance fuel nozzle designs. An experimental program is planned to investigate the fuel nozzle concepts in a flametube test rig. Currently, a hydrogen system is being installed in cell 23 at NASA Glenn Research Center's Research Combustion Laboratory. Testing will be conducted on a variety of fuel nozzle concepts up to combustion pressures of 350 psia and inlet air temperatures of 1200 F. Computational fluid dynamics calculations, with the Glenn developed National Combustor Code, are being performed to optimize the fuel nozzle designs.

Smith, Timothy D.↗

NASA NTRS1968

Advances in solid-fuel propulsion systems for tactical rockets

The objective of this paper is to present a brief survey of three areas in which advances of solid propulsion have enabled improved design of tactical rockets. The three areas are microwave attenuation, acceleration-combustion interactions, and performance optimization. In each of the three areas, improved understanding has significantly contributed to rocket technology. The problems remaining are far from solved, however, and the three subjects are fruitful areas for fundamental investigations.

Charles B Henderson↗