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High-altitude simulator reduced power requirements. Test cell uses its exhaust-capture duct only to remove gases from engine; cooling air evacuated through separate path by auxiliary suction system. This way, capture duct cross-sectional area kept close to exhaust jet area, leading to greatly improved recovery performance.
Nuclear Thermal Propulsion (NTP) engines have been deemed a key technology to enable human missions to Mars due to their high efficiency, also known as specific impulse (Isp). Ground testing the NTP engine is critical in maturing the technology and increasing the design’s Technology Readiness Level (TRL), thus mitigating risk from NTP engine performance/operations. NTP engine development began with open-air ground testing through the Rover/NERVA program back in the 1960s when regulatory requirements were not as stringent as they are today. Due to the formation of regulatory bodies, increase in oversight and environmental requirements, the exhaust gas released from NTP engines must be captured or processed to gain approval in the case that the exhaust gas contains fission products from the nuclear fuel elements within the reactor. Ground test campaigns following Rover/NERVA focused on the certification of a full scale NTP engine, which led to exhaust processing systems such as the Rocket Exhaust Capture System (RECS) and Real Time (RT) exhaust processing. These systems were deemed favorable for regulatory compliance but have a high initial investment cost. Reassurance on the feasibility of ground testing and the NTP engine technology likely need to be achieved before NASA invests in these systems. Recently the objectives for NTP engine ground testing have shifted from certification testing of a full scale engine to demonstration testing of a subscale engine. The shift to demonstration testing allows for a shorter testing duration and a lower operational thrust (for demo testing purposes only) to demonstrate the NTP engine (5k-12.5k lbf). Due to these factors, the infrastructure, consumables, total footprint, and exhaust system complexity are able to be drastically reduced, thus reducing cost significantly. The High-pressure Exhaust Capture System (HECS) concept was designed for a NTP engine ground test demonstration. The HECS concept greatly reduces cost compared to previous concepts and suggests favorable regulatory acceptance due to its ability to capture all of the exhaust gas from the NTP engine.
Nuclear Thermal Propulsion (NTP) engines have been deemed a key technology to enable human missions to Mars due to their high efficiency, also known as specific impulse (Isp). Ground testing the NTP engine is critical in maturing the technology and increasing the design’s Technology Readiness Level (TRL), thus mitigating risk from NTP engine performance/operations. NTP engine development began with open-air ground testing through the Rover/NERVA program back in the 1960s when regulatory requirements were not as stringent as they are today. Due to the formation of regulatory bodies, increase in oversight and environmental requirements, the exhaust gas released from NTP engines must be captured or processed to gain approval in the case that the exhaust gas contains fission products from the nuclear fuel elements within the reactor. Ground test campaigns following Rover/NERVA focused on the certification of a full scale NTP engine, which led to exhaust processing systems such as the Rocket Exhaust Capture System (RECS) and Real Time (RT) exhaust processing. These systems were deemed favorable for regulatory compliance but have a high initial investment cost. Reassurance on the feasibility of ground testing and the NTP engine technology likely need to be achieved before NASA invests in these systems. Recently the objectives for NTP engine ground testing have shifted from certification testing of a full scale engine to demonstration testing of a subscale engine. The shift to demonstration testing allows for a shorter testing duration and a lower operational thrust (for demo testing purposes only) to demonstrate the NTP engine (5k-12.5k lbf). Due to these factors, the infrastructure, consumables, total footprint, and exhaust system complexity are able to be drastically reduced, thus reducing cost significantly. The High-pressure Exhaust Capture System (HECS) concept was designed for a NTP engine ground test demonstration. The HECS concept greatly reduces cost compared to previous concepts and suggests favorable regulatory acceptance due to its ability to capture all of the exhaust gas from the NTP engine.
One of the biggest challenges of manned spaceflight beyond low earth orbit and the moon is harmful radiation that astronauts would be exposed to on their long journey to Mars and further destinations. Using nuclear energy has the potential to be a more effective means of propulsion compared to traditional chemical engines (higher specific impulse). An upper stage nuclear engine would allow astronauts to reach their destination faster and more fuel efficiently. Testing these engines poses engineering challenges due to the need to totally capture the engine exhaust. The Thermal Propulsion Capture System is a concept for cost effectively and safely testing Nuclear Thermal Engines. Nominally, hydrogen exhausted from the engine is not radioactive, but is treated as such in case of fuel element failure. The Thermal Propulsion Capture System involves injecting liquid oxygen to convert the hydrogen exhaust into steam. The steam is then cooled and condensed into liquid water to allow for storage. The Thermal Propulsion Capture System concept for ground testing of a nuclear powered engine involves capturing the engine exhaust to be cooled and condensed before being stored. The hydrogen exhaust is injected with liquid oxygen and burned to form steam. That steam must be cooled to saturation temperatures before being condensed into liquid water. A crossflow heat exchanger using water as a working fluid will be designed to accomplish this goal. Design a cross flow heat exchanger for the Thermal Propulsion Capture System testing which: Eliminates the need for water injection cooling, Cools steam from 5800 F to saturation temperature, and Is efficient and minimizes water requirement.
The global fuel consumption by commercial airlines has increased each year since 2009 and is predicted to reach an all-time high of 97 billion gallons in 2019. There is also an environmental impact from this: CO2 emissions from commercial passenger and freight operations totaled 918 Mt in 2018 (ICCT, 2019), or around 2.5% of global energy-related CO2 emissions. Passenger transport accounted for 81% of the total. Emissions from aviation have grown 32% over the past five years. Coupled with this aspect, there is a continuous and growing need to satisfy ever-growing electrical power needs on commercial and military aircraft. All the armed services (Army, Navy, and Air Force) are continuously trying to enhance UAV (unmanned aerial vehicle) endurance and range across a broad fleet of different aircraft. The commercial Boeing 787 requires about 1.2MWe and that is expected to grow. Current technologies used to supply increased on-board electrical power are generally: 1) “burn more fuel and convert through on-board generators” and 2) use additional heavy (i.e., weight-inefficient) and sometimes unsafe battery systems on-board the aircraft. The aircraft industry is seeking new, innovative ways to satisfy this increasing power demand. One as-yet-untapped power source is the enormous amount of “waste” thermal energy flowing out the jet engine exhaust; some estimates in smaller “by-pass” flow jet engines is several hundreds of kilowatts (e.g., Pratt & Whitney Canada PW545B turbofan). This quantity is much higher in large jet engines associated with commercial aircraft. This large waste thermal energy manifests itself in large temperature differences within the by-pass-flow engine exhaust system relative to outside ambient conditions, because of the actual by-pass engine design configuration. There is strong need to develop thermal technologies and systems that could harness and convert at least a portion of this thermal energy into useful electrical energy to satisfy growing on-board electrical needs. In addition, there is a strong desire within the aircraft and engine manufacturing community to reduce the “carbon footprint” of the industry though reduced fuel usage worldwide. NASA has a robust aircraft electrification program to meet these desires and support industry in its aircraft electrification objectives. This program is integrating thermoacoustic systems, advanced lightweight heat exchanger technology, and advanced heat pipe technology to capture and transport large amounts of engine waste thermal energy for on-board power conversion, advanced heat-pump cooling, and exergy enhancement (i.e., temperature lift). Advanced lightweight heat exchangers are envisioned to capture engine exhaust thermal energy at approximately 673 K and deliver it to efficient thermoacoustic power conversion systems operating at temperature ratios (Thot/Tcold) > 1.6. Advanced heat pipe systems are envisioned to transport thermal energy from low temperature sources, through thermoacoustic heat pumps, to high temperature needs such as wing anti-icing, fuel pre-heating, and combustion air pre-heating. The paper will discuss the current state-of-the-art, objectives, system design architecture, and remaining technical challenges in system formulation within the NASA aircraft electrification program.
Driven by the need for low production costs, electronics cooling fans have evolved differently than the bladed components of gas turbine engines which incorporate multiple technologies to enhance performance and durability while reducing noise emissions. Drawing upon NASA Glenn's experience in the measurement and prediction of gas turbine engine aeroacoustic performance, tests have been conducted to determine if these tools and techniques can be extended for application to the aerodynamics and acoustics of electronics cooling fans. An automated fan plenum installed in NASA Glenn's Acoustical Testing Laboratory was used to map the overall aerodynamic and acoustic performance of a spaceflight qualified 80 mm diameter axial cooling fan. In order to more accurately identify noise sources, diagnose performance limiting aerodynamic deficiencies, and validate noise prediction codes, additional aerodynamic measurements were recorded for two operating points: free delivery and a mild stall condition. Non-uniformities in the fan s inlet and exhaust regions captured by Particle Image Velocimetry measurements, and rotor blade wakes characterized by hot wire anemometry measurements provide some assessment of the fan aerodynamic performance. The data can be used to identify fan installation/design changes which could enlarge the stable operating region for the fan and improve its aerodynamic performance and reduce noise emissions.
We propose an approach to formally verify Plural specifications based on access permissions and typestates, by model-checking automatically generated abstract state-machines. Our exhaustive approach captures all the possible behaviors of abstract concurrent programs implementing the specification. We describe the formal methodology employed by our technique and provide an example as proof of concept for the state-machine construction rules. The implementation of a fully automated algorithm to generate and verify models, currently underway, provides model checking support for the Plural tool, which currently supports only program verification via data flow analysis (DFA).
Simulated altitude testing of a two-dimensional, convergent-divergent, thrust vectoring and reversing exhaust nozzle was accomplished. An important objective of this test was to develop test hardware and techniques to properly operate a vectoring and reversing nozzle within the confines of an altitude test facility. This report presents detailed information on the major test support systems utilized, the operational performance of the systems and the problems encountered, and test equipment improvements recommended for future tests. The most challenging support systems included the multi-axis thrust measurement system, vectored and reverse exhaust gas collection systems, and infrared temperature measurement systems used to evaluate and monitor the nozzle. The feasibility of testing a vectoring and reversing nozzle of this type in an altitude chamber was successfully demonstrated. Supporting systems performed as required. During reverser operation, engine exhaust gases were successfully captured and turned downstream. However, a small amount of exhaust gas spilled out the collector ducts' inlet openings when the reverser was opened more than 60 percent. The spillage did not affect engine or nozzle performance. The three infrared systems which viewed the nozzle through the exhaust collection system worked remarkably well considering the harsh environment.
Characteristics of airframe-integrated scramjet (AIS) aerospacecraft are studied using elementary and a recently developed AIS analysis code. Of principal interest is the definition of the AIS and what concepts offer the most potential. One of the concepts is selected for a limited optimization study aimed at defining the relationship of exhaust area to performance potential. The study shows that, if the AIS vehicle is to be fully constrained within the 'optimum' flowpath envelope, large values of exhaust-area-to-capture-area ratio are desired. A benefit of this choice is that performance at the very highest airbreather speeds is improved and, thus, may delay the need to switch to rocket power.
High efficiency rocket propulsion systems are essential for humanity to venture beyond the moon. Nuclear Thermal Propulsion (NTP) is a promising alternative to conventional chemical rockets with relatively high thrust and twice the efficiency of highest performing chemical propellant engines. NTP utilizes the coolant of a nuclear reactor to produce propulsive thrust. An NTP engine produces thrust by flowing hydrogen through a nuclear reactor to cool the reactor, heating the hydrogen and expelling it through a rocket nozzle. The hot gaseous hydrogen is nominally expected to be free of radioactive byproducts from the nuclear reactor; however, it has the potential to be contaminated due to off-nominal engine reactor performance. NTP ground testing is more difficult than chemical engine testing since current environmental regulations do not allow/permit open air testing of NTP as was done in the 1960's and 1970's for the Rover/NERVA program. A new and innovative approach to rocket engine ground test is required to mitigate the unique health and safety risks associated with the potential entrainment of radioactive waste from the NTP engine reactor core into the engine exhaust. Several studies have been conducted since the ROVER/NERVA program in the 1970's investigating NTP engine ground test options to understand the technical feasibility, identify technical challenges and associated risks and provide rough order of magnitude cost estimates for facility development and test operations. The options can be divided into two distinct schemes; (1) real-time filtering of the engine exhaust and its release to the environment or (2) capture and storage of engine exhaust for subsequent processing.
A two-dimensional convergent-divergent exhaust nozzle designed and fabricated by Pratt and Whitney Aircraft was installed on a PW1128 turbofan engine and tested during thrust reverser operation in an altitude facility at NASA Lewis Research Center. A unique collection system was used to capture the thrust reverser exhaust gas and transport it to the primary exhaust collector. Tests were conducted at three flight conditions with varying amounts of thrust reverse at each condition. Some reverser exhaust gas spillage by the collection system was encountered but engine performance was unaffected at all flight conditions tested. Based on the results of this test program, the feasibility of altitude testing of advanced multi-function exhaust nozzle systems has been demonstrated.
A two-dimensional convergent-divergent exhaust nozzle designed and fabricated by Pratt and Whitney Aircraft was installed on a PW1128 turbofan engine and tested during thrust reverser operation in an altitude facility at NASA Lewis Research Center. A unique collection system was used to capture the thrust reverser exhaust gas and transport it to the primary exhaust collector. Tests were conducted at three flight conditions with varying amounts of thrust reverse at each condition. Some reverser exhaust gas spillage by the collection system was encountered but engine performance was unaffected at all flight conditions tested. Based on the results of this test program, the feasibility of altitude testing of advanced multifunction exhaust nozzle systems has been demonstrated.
Simulations of exhaust nozzle flows are typically conducted assuming the gas is calorically perfect, and typically modeled as air. However the gas inside a real nozzle is generally composed of combustion products whose thermodynamic properties may differ. In this study, the effect of gas model assumption on exhaust nozzle simulations is examined. The three methods considered model the nozzle exhaust gas as calorically perfect air, a calorically perfect exhaust gas mixture, and a frozen exhaust gas mixture. In the latter case the individual non-reacting species are tracked and modeled as a gas which is only thermally perfect. Performance parameters such as mass flow rate, gross thrust, and thrust coefficient are compared as are mean flow and turbulence profiles in the jet plume region. Nozzles which operate at low temperatures or have low subsonic exit Mach numbers experience relatively minor temperature variations inside the nozzle, and may be modeled as a calorically perfect gas. In those which operate at the opposite extreme conditions, variations in the thermodynamic properties can lead to different expansion behavior within the nozzle. Modeling these cases as a perfect exhaust gas flow rather than air captures much of the flow features of the frozen chemistry simulations. Use of the exhaust gas reduces the nozzle mass flow rate, but has little effect on the gross thrust. When reporting nozzle thrust coefficient results, however, it is important to use the appropriate gas model assumptions to compute the ideal exit velocity. Otherwise the values obtained may be an overly optimistic estimate of nozzle performance.
A preliminary design of a lunar landing and launch facility for a Phase 3 lunar base is formulated. A single multipurpose vehicle for the lunar module is assumed. Three traffic levels are envisioned: 6, 12, and 24 landings/launches per year. The facility is broken down into nine major design items. A conceptual description of each of these items is included. Preliminary sizes, capacities, and/or other relevant design data for some of these items are obtained. A quonset hut tent-like structure constructed of aluminum rods and aluminized mylar panels is proposed. This structure is used to provide a constant thermal environment for the lunar modules. A structural design and thermal analysis is presented. Two independent designs for a bridge crane to unload/load heavy cargo from the lunar module are included. Preliminary investigations into cryogenic propellant storage and handling, landing/launch guidance and control, and lunar module maintenance requirements are performed. Also, an initial study into advanced concepts for application to Phase 4 or 5 lunar bases has been completed in a report on capturing, condensing, and recycling the exhaust plume from a lunar launch.
A new exhaust diffuser concept for jet engine altitude test cells which greatly reduces operating power and cost requirements for exhausters is discussed. The concept utilizes the capture duct as an efficient diffuser only, while evacuating the secondary air via a separate path using an auxiliary suction system. Implementation of the concept would reduce the peak exhauster power requirement during a TF-30 altitude test by 48 percent and the overall exhaust power cost of the test program by 41 percent. The design accommodates various engine sizes and can achieve optimum pressure recovery performance during both A/B and IRP modes of engine operation. The pressure recovery performance of the proposed exhaust diffusers does not deteriorate with increasing cooling air fraction. The disadvantages of the proposed scheme are: increased mechanical complexity of the extended variable geometry diffuser duct and the need for an auxiliary suction system for evacuating cell-cooling air.
A Navier-Stokes computer code was validated using a number of two- and three-dimensional configurations for both laminar and turbulent flows. The validation data covers a range of freestream Mach numbers from 3 to 14, includes wall pressures, velocity profiles, and skin friction. Nozzle flow fields computed for a generic scramjet nozzle from Mach 3 to 20, wall pressures, wall skin friction values, heat transfer values, and overall performance are presented. In addition, three-dimensional solutions obtained for two asymmetric, single expansion ramp nozzles at a pressure ratio of 10 consists of the internal expansion region in the converging/diverging sections and the external supersonic exhaust in a quiescent ambient environment. The fundamental characteristics that were captured successfully include expansion fans; Mach wave reflections; mixing layers; and nonsymmetrical, multiple inviscid cell, supersonic exhausts. Comparison with experimental data for wall pressure distributions at the center planes shows good agreement.
A Navier-Stokes computer code was validated using a number of two- and three-dimensional configurations for both laminar and turbulent flows. The validation data covers a range of freestream Mach numbers from 3 to 14, including wall pressures, velocity pressure, and skin friction. Nozzle flow fields computed for a generic scramjet nozzle from Mach 3 to 20, wall pressures, wall skin friction values, heat transfer values, and overall performance are presented. In addition, three-dimensional solutions obtained for two asymmetric, single expansion ramp nozzles at a pressure ratio of 10 consists of the internal expansion region in the converging/diverging sections and the external superonic exhaust in a quiescent ambient environment. The fundamental characteristics that were captured successfully include expansion fans; Mach wave reflections; mixing layers; and nonsymmetrical, multiple inviscid cell, supersonic exhausts. Comparison with experimental data for wall pressure distributions at the center planes shows good agreement.
The flow fields from a set of 50.8 mm diameter circular nozzles were characterized using both streamwise and cross-stream 3-component Stereo Particle Image Velocimetry (SPIV). The test matrix of nozzles included 15 different chevron nozzle designs and one baseline, circularly symmetric nozzle. Nozzle jet operating conditions ranged from acoustic Mach numbers of 0.9 to 1.5, with static temperature ratios ranging between 0.84 and 2.7. Detailed surveys of the single jet flows were performed to capture three-dimensional features of the turbulent exhaust jet evolution. Cross-flow planar measurements were obtained at twelve axial locations, ranging from 0.1 to 20 nozzle diameters downstream of the nozzle exit planes. Streamwise measurements, along the jet centerlines, were obtained at ten partially overlapping downstream locations, providing complete axial surveys over a region extending beyond 20 nozzle diameters downstream of the nozzle exit planes. In both optical configurations, the measurement planes were sized to completely capture the fully turbulent jet shear layer growth. The measured three-dimensional mean and turbulent velocity fields, along with computed second order statistics including axial vorticity and turbulent kinetic energy, were evaluated for all test points. Well-defined streamwise vortex structures in the jet shear layers were measured and reported.