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NASA NTRS1996

Mach 5 to 7 RBCC Propulsion System Testing at NASA-LeRC HTF

A series of Mach 5 to 7 freejet tests of a Rocket Based Combined Cycle (RBCC) engine were cnducted at the NASA Lewis Research Center (LERC) Hypersonic Tunnel Facility (HTF). This paper describes the configuration and operation of the HTF and the RBCC engine during these tests. A number of facility support systems are described which were added or modified to enhance the HTF test capability for conducting this experiment. The unfueled aerodynamic perfor- mance of the RBCC engine flowpath is also presented and compared to sub-scale test results previously obtained in the NASA LERC I x I Supersonic Wind Tunnel (SWT) and to Computational Fluid Dynamic (CFD) analysis results. This test program demonstrated a successful configuration of the HTF for facility starting and operation with a generic RBCC type engine and an increased range of facility operating conditions. The ability of sub-scale testing and CFD analysis to predict flowpath performance was also shown. The HTF is a freejet, blowdown propulsion test facility that can simulate up to Mach 7 flight conditions with true air composition. Mach 5, 6, and 7 facility nozzles are available, each with an exit diameter of 42 in. This combination of clean air, large scale, and Mach 7 capabilities is unique to the HTF. This RBCC engine study is the first engine test program conducted at the HTF since 1974.

Perkins, H. Douglas↗

NASA NTRS2010

The Mothball, Sustainment, and Proposed Reactivation of the Hypersonic Tunnel Facility (HTF) at NASA Glenn Research Center Plum Brook Station

The Hypersonic Tunnel Facility (HTF) located at the NASA Glenn Research Center s Plum Brook Station in Sandusky, Ohio, is the nation s only large-scale, non-vitiated, hypersonic propulsion test facility. The HTF, with its 4-story graphite induction heater, is capable of duplicating Mach 5, 6, and 7 flight conditions. This unique propulsion system test facility has experienced several standby and reactivation cycles. The intent of the paper is to overview the HTF capabilities to the propulsion community, present the current status of HTF, and share the lessons learned from putting a large-scale facility into mothball status for a later restart

Thomas, Scott R.↗

NASA NTRS1995

Operating capability and current status of the reactivated NASA Lewis Research Center Hypersonic Tunnel Facility

The NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) is a free-jet, blowdown propulsion test facility that can simulate up to Mach-7 flight conditions with true air composition. Mach-5, -6, and -7 nozzles, each with a 42 inch exit diameter, are available. Previously obtained calibration data indicate that the test flow uniformity of the HTF is good. The facility, without modifications, can accommodate models approximately 10 feet long. The test gas is heated using a graphite core induction heater that generates a nonvitiated flow. The combination of clean-air, large-scale, and Mach-7 capabilities is unique to the HTF and enables an accurate propulsion performance determination. The reactivation of the HTF, in progress since 1990, includes refurbishing the graphite heater, the steam generation plant, the gaseous oxygen system, and all control systems. All systems were checked out and recertified, and environmental systems were upgraded to meet current standards. The data systems were also upgraded to current standards and a communication link with NASA-wide computers was added. In May 1994, the reactivation was complete, and an integrated systems test was conducted to verify facility operability. This paper describes the reactivation, the facility status, the operating capabilities, and specific applications of the HTF.

Thomas, Scott R.↗

NASA NTRS1995

Operating capability and current status of the reactivated NASA Lewis Research Center hypersonic tunnel facility

The NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) is a free-jet, blowdown propulsion test facility that can simulate up to Mach-7 flight conditions with true air composition. Mach-5, -6, and -7 nozzles, each with a 42-in. exit diameter, are available. Previously obtained calibration data indicate that the test flow uniformity of the HTF is good. The facility, without modifications, can accomodate models approximately 10 ft long. The test gas is heated using a graphite core induction heater that generates a nonvitiated flow. The combination of clean-air, large-scale, and Mach-7 capabilities is unique to the HTF and enables an accurate propulsion performance determination. The reactivation of the HTF, in progress since 1990, includes refurbishing the graphite heater, the steam generation plant, the gaseous oxygen system, and all control systems. All systems were checked out and recertified, and environmental systems were upgraded to meet current standards. The data systems were also upgraded to current standards and a communication link with NASA-wide computers was added. In May 1994, the reactivation was complete, and an integrated systems test was conducted to verify facility operability. This paper describes the reactivation activities, the facility status, the operating capabilities, and specific applications of the HTF.

Thomas, S.↗

NASA NTRS2007

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗

NASA NTRS1987

Reactivation study for NASA Lewis Research Center's hypersonic tunnel facility

The Hypersonic Tunnel Facility (HTF) at NASA Lewis Research Center's Plum Brook Station is a blowdown, free-jet, nonvitiated propulsion facility capable of Mach 5, 6, and 7 with true temperature, altitude, and air composition simulation. The facility has been in a deactivated status for 13 years. Discussed are the capabilities of HTF, and the results of a deactivation study recently conducted to determine the cost, schedule, and technical effort required to restore HTF to its original design operating capabilities are summarized.

Haas, Jeffrey E.↗

NASA NTRS1987

Reactivation study for NASA Lewis Research Center's Hypersonic Tunnel Facility

Haas, Jeffrey E.↗

NASA NTRS1987

On the noncoplanarity of the magnetic field within a fast collisionless shock

Within the magnetic ramp of fast collisionless plasma shocks observed with spacecraft instruments and simulated numerically, the magnetic field undergoes an excursion out of the plane of coplanarity. This rotation is consistently in the direction such that the electrostatic potential jump across the shock, as measured in the de Hoffman-Teller frame of the reference (HTF), is about 2-6 times smaller than the electrostatic potential jump measured in the normal incidence frame. The preferred direction is consistent with a basic whistler mode transition between the upstream and downstream orientations. The potential jump in the HTF is considerably smaller than the change in bulk flow energy across the shock, confirming the recent suggestion that magnetic forces contribute importantly to the slowing of the plasma in that frame. A further consequence is that suprathermal particles leaking back into the upstream region across the shock do not gain much energy from the cross-shock electric field.

Thomsen, M. F.↗

NASA NTRS2000

Restoration of the Hypersonic Tunnel Facility at NASA Glenn Research Center, Plum Brook Station

The NASA Glenn Research Center's Hypersonic Tunnel Facility (HTF), located at the Plum Brook Station in Sandusky, Ohio, is a non-vitiated, free-jet facility, capable of testing large-scale propulsion systems at Mach Numbers from 5 to 7. As a result of a component failure in September of 1996, a restoration project was initiated in mid- 1997 to repair the damage to the facility. Following the 2-1/2 year effort, the HTF has been returned to an operational condition. Significant repairs and operational improvements have been implemented in order to ensure facility reliability and personnel safety. As of January 2000, this unique, state-of-the-art facility was ready for integrated systems testing.

Woodling, Mark A.↗

NASA NTRS1997

Evaluation of an Ejector Ramjet Based Propulsion System for Air-Breathing Hypersonic Flight

A Rocket Based Combined Cycle (RBCC) engine system is designed to combine the high thrust to weight ratio of a rocket along with the high specific impulse of a ramjet in a single, integrated propulsion system. This integrated, combined cycle propulsion system is designed to provide higher vehicle performance than that achievable with a separate rocket and ramjet. The RBCC engine system studied in the current program is the Aerojet strutjet engine concept, which is being developed jointly by a government-industry team as part of the Air Force HyTech program pre-PRDA activity. The strutjet is an ejector-ramjet engine in which small rocket chambers are embedded into the trailing edges of the inlet compression struts. The engine operates as an ejector-ramjet from take-off to slightly above Mach 3. Above Mach 3 the engine operates as a ramjet and transitions to a scramjet at high Mach numbers. For space launch applications the rockets would be re-ignited at a Mach number or altitude beyond which air-breathing propulsion alone becomes impractical. The focus of the present study is to develop and demonstrate a strutjet flowpath using hydrocarbon fuel at up to Mach 7 conditions. Freejet tests of a candidate flowpath for this RBCC engine were conducted at the NASA Lewis Research Center's Hypersonic Tunnel Facility between July and September 1996. This paper describes the engine flowpath and installation, outlines the primary objectives of the program, and describes the overall results of this activity. Through this program 15 full duration tests, including 13 fueled tests were made. The first major achievement was the further demonstration of the HTF capability. The facility operated at conditions up to 1950 K and 7.34 MPa, simulating approximately Mach 6.6 flight. The initial tests were unfueled and focused on verifying both facility and engine starting. During these runs additional aerodynamic appliances were incorporated onto the facility diffuser to enhance starting. Both facility and engine starting were achieved. Further, the static pressure distributions compared well with the results previously obtained in a 40% subscale flowpath study conducted in the LERC 1X1 supersonic wind tunnel (SWT), as well as the results of CFD analysis. Fueled performance results were obtained for the engine at both simulated Mach 6 (1670 K) and Mach 6.6 (1950 K) conditions. For all these tests the primary fuel was liquid JP-10 with gaseous silane (a mixture of 20% SiH4 and 80% H2 by volume) as an ignitor/pilot. These tests verified performance of this engine flowpath in a freejet mode. High combustor pressures were reached and significant changes in axial force were achieved due to combustion. Future test plans include redistributing the fuel to improve mixing, and consequently performance, at higher equivalence ratios.

Thomas, Scott R.↗

NASA NTRS1999

Plumbrook Hypersonic Tunnel Facility Graphite Furnace Degradation Mechanisms

A recent rebuild revealed extensive degradation to the large graphite induction furnace in the Hypersonic Tunnel Facility (HTF). This damage to the graphite blocks and insulating felt is examined and modeled with thermochemical equilibrium codes. The primary reactions appear to be with water vapor and the nitrogen purge gas. Based on these conclusions, several changes are recommended. An inert purge gas (e.g. argon or helium) and controlling and monitoring water vapor to about 10 ppm should decrease the damage substantially.

Jacobson, Nathan S.↗

NASA NTRS2001

Parametric Data from a Wind Tunnel Test on a Rocket-Based Combined-Cycle Engine Inlet

A 40-percent scale model of the inlet to a rocket-based combined-cycle (RBCC) engine was tested in the NASA Glenn Research Center 1- by 1-Foot Supersonic Wind Tunnel (SWT). The full-scale RBCC engine is scheduled for test in the Hypersonic Tunnel Facility (HTF) at NASA Glenn's Plum Brook Station at Mach 5 and 6. This engine will incorporate the configuration of this inlet model which achieved the best performance during the present experiment. The inlet test was conducted at Mach numbers of 4.0, 5.0, 5.5, and 6.0. The fixed-geometry inlet consists of an 8 deg.. forebody compression plate, boundary layer diverter, and two compressive struts located within 2 parallel sidewalls. These struts extend through the inlet, dividing the flowpath into three channels. Test parameters investigated included strut geometry, boundary layer ingestion, and Reynolds number (Re). Inlet axial pressure distributions and cross-sectional Pitot-pressure surveys at the base of the struts were measured at varying back-pressures. Inlet performance and starting data are presented. The inlet chosen for the RBCC engine self-started at all Mach numbers from 4 to 6. Pitot-pressure contours showed large flow nonuniformity on the body-side of the inlet. The inlet provided adequate pressure recovery and flow quality for the RBCC cycle even with the flow separation.

Fernandez, Rene↗

NASA NTRS2001

The NASA Glen Research Center's Hypersonic Tunnel Facility

The NASA Glenn Research Center's Hypersonic Tunnel Facility (HTF) is a blow-down, freejet wind tunnel that provides true enthalpy flight conditions for Mach numbers of 5, 6, and 7. The Hypersonic Tunnel Facility is unique due to its large scale and use of non-vitiated (clean air) flow. A 3MW graphite core storage heater is used to heat the test medium of gaseous nitrogen to the high stagnation temperatures required to produce true enthalpy conditions. Gaseous oxygen is mixed into the heated test flow to generate the true air simulation. The freejet test section is 1.07m (42 in.) in diameter and 4.3m (14 ft) in length. The facility is well suited for the testing of large scale airbreathing propulsion systems. In this chapter, a brief history and detailed description of the facility are presented along with a discussion of the facility's application towards hypersonic airbreathing propulsion testing.

Woike, Mark R.↗

NASA NTRS1996

Mach 6 Integrated Systems Tests of Lewis' Hypersonic Tunnel Facility

A series of 15 integrated systems tests were conducted at the NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) with test conditions simulating flight up to Mach 6. Facility stagnation conditions up to 3050 R and 1050 psia were obtained with typical test times of 20 to 45 sec.

Source record↗

NASA NTRS2007

A Discussion on Personnel Exposure to Posttest Byproducts from a 50-cal. Light Gas Gun

In January of 2002, employees working in the Hypervelocity Test Facility (HTF) at White Sands Test Facility (WSTF) began to notice common physical complaints. These included loss of smell, loss of taste, skin irritation, a burning sensation of the mucus membranes, and redness and chapping of the lips. These conditions extended to home during the weekends and throughout holiday breaks as well. Concerns about air contaminants were raised with regard to the operation of the .50-cal. two-stage light gas gun (2SLGG). Employees suspected that these conditions might be caused by air contaminants from small leaks at the gun pump tube joint at the breech, and exhaust gas entrainment into the WAC systems. The WSTF Industrial Hygienist (IH) was notified and samples were collected using the MIRAN infrared spectrometer (real time) air sampler on 08 January 2002 at the SO-cal. gun. The results from this screening test suggested the need for more detailed investigations with analytical sampling and analysis.

Henderson, Don↗

NASA NTRS2010

A Heat Transfer Investigation of Liquid and Two-Phase Methane

A heat transfer investigation was conducted for liquid and two-phase methane. The tests were conducted at the NASA Glenn Research Center Heated Tube Facility (HTF) using resistively heated tube sections to simulate conditions encountered in regeneratively cooled rocket engines. This testing is part of NASA s Propulsion and Cryogenics Advanced Development (PCAD) project. Nontoxic propellants, such as liquid oxygen/liquid methane (LO2/LCH4), offer potential benefits in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications. Regeneratively cooled thrust chambers are one solution for high performance, robust LO2/LCH4 engines, but cooling data on methane is limited. Several test runs were conducted using three different diameter Inconel 600 tubes, with nominal inner diameters of 0.0225-, 0.054-, and 0.075-in. The mass flow rate was varied from 0.005 to 0.07 lbm/sec. As the current focus of the PCAD project is on pressure fed engines for LO2/LCH4, the average test section outlet pressures were targeted to be 200 psia or 500 psia. The heat flux was incrementally increased for each test condition while the test section wall temperatures were monitored. A maximum average heat flux of 6.2 Btu/in.2 sec was achieved and, at times, the temperatures of the test sections reached in excess of 1800 R. The primary objective of the tests was to produce heat transfer correlations for methane in the liquid and two-phase regime. For two-phase flow testing, the critical heat flux values were determined where the fluid transitions from nucleate boiling to film boiling. A secondary goal of the testing was to measure system pressure drops in the two-phase regime.

VanNoord, Jonathan↗