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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Vortex Flow and Cavitation in Liquid Injection: A Comparison between High-Fidelity CFD Simulations and Experimental Visualizations on Transparent Nozzle Replicas

Experimental instantaneous shadowgraph visualizations on transparent glass nozzle replicas of high-pressure fuel injectors have been used to validate a novel in-house high-fidelity LES-VOF multiphase solver, to study the evolution of vortex flow and fuel cavitation. Both experiments and simulations capture the formation of an unsteady vapor structure inside the nozzle volume, which is referred to as 'string-cavitation'; strings are found at the core of the recirculation zones. Furthermore, high-fidelity simulations provide a very detailed insight into the vortex generation in the injector nozzle; strings appear within the time scales that are relevant for fast injection events (on the order of 0.1 milliseconds) and, for the problem under consideration, their generation seems mostly related to the flow pattern in the sac. It is also shown that vortexes interact, merge till they disrupt and favor the temporary inception of shear cavitation.

3-phase LES-VOF solver↗
DOE OSTI2020

Stereoscopic high-speed microscopy to understand transient internal flow processes in high-pressure nozzles

The flow and cavitation behavior inside fuel injectors is known to affect spray development, mixing and combustion characteristics. We discuss that while diesel fuel injectors with converging and hydro-eroded holes are generally known to limit cavitation and feature higher discharge coefficients during the steady period of injection, less is known about the flow during transient periods corresponding to needle opening and closing. Multiple injection strategies involve short injections, multiplying these aspects and giving them a growing importance as part of the fuel delivery process. In this study, single-hole transparent nozzles were manufactured with the same hole inlet radius and diameter as the Engine Combustion Network Spray D nozzle, mounted to a modified version of a common-rail Spray A injector body and needle. Needle opening and closing periods were visualized with stereoscopic high-speed microscopy at injection pressures relevant to modern diesel engines. Time-resolved sac pressure was extracted via elastic deformation analysis of the transparent nozzles. Sources of cavitation were observed and tracked, enabling the identification of a gas exchange process after the end of injection with ingestion of chamber gas into the sac and orifice. We observed that the gas exchange contributed widely to disrupting the start of injection and outlet flow during the subsequent injection event.

42 ENGINEERING↗
NASA NTRS2008

Influence of Reduced Mass Flow Rate and Chamber Backpressure on Swirl Injector Fluid Mechanics

Industry interest in variable-thrust liquid rocket engines places a demand on engine injector technology to operate over a wide range of liquid mass flow rates and chamber backpressures. One injection technology of current interest for variable thrust applications is an injector design with swirled fluids. Current swirl injector design methodologies do not take into account how swirl injector design parameters respond to elevated chamber backpressures at less than design mass flow rates. The current work was created to improve state-of-the-art swirl injector design methods in this area. The specific objective was to study the effects of elevated chamber backpressure and off-design mass flow rates on swirl injector fluid mechanics. Using a backpressure chamber with optical access, water was flowed through a swirl injector at various combinations of chamber backpressure and mass flow rates. The film thickness profile down the swirl injector nozzle section was measured through a transparent nozzle section of the injector. High speed video showed measurable increases in the film thickness profile with application of chamber backpressure and mass flow rates less than design. At prescribed combinations of chamber backpressure and injected mass flow rate, a discrete change in the film thickness profile was observed. Measured injector discharge coefficient values showed different trends with increasing chamber backpressure at low mass flow rates as opposed to near-design mass flow rates. Downstream spray angles showed classic changes in morphology as the mass flow rate was decreased below the design value. Increasing chamber backpressure decreased the spray angle at any injection mass flow rate. Experimental measurements and discussion of these results are reported in this paper.

Kenny, R Jeremy↗
NASA NTRS2013

Orion MPCV GN and C End-to-End Phasing Tests

End-to-end integration tests are critical risk reduction efforts for any complex vehicle. Phasing tests are an end-to-end integrated test that validates system directional phasing (polarity) from sensor measurement through software algorithms to end effector response. Phasing tests are typically performed on a fully integrated and assembled flight vehicle where sensors are stimulated by moving the vehicle and the effectors are observed for proper polarity. Orion Multi-Purpose Crew Vehicle (MPCV) Pad Abort 1 (PA-1) Phasing Test was conducted from inertial measurement to Launch Abort System (LAS). Orion Exploration Flight Test 1 (EFT-1) has two end-to-end phasing tests planned. The first test from inertial measurement to Crew Module (CM) reaction control system thrusters uses navigation and flight control system software algorithms to process commands. The second test from inertial measurement to CM S-Band Phased Array Antenna (PAA) uses navigation and communication system software algorithms to process commands. Future Orion flights include Ascent Abort Flight Test 2 (AA-2) and Exploration Mission 1 (EM-1). These flights will include additional or updated sensors, software algorithms and effectors. This paper will explore the implementation of end-to-end phasing tests on a flight vehicle which has many constraints, trade-offs and compromises. Orion PA-1 Phasing Test was conducted at White Sands Missile Range (WSMR) from March 4-6, 2010. This test decreased the risk of mission failure by demonstrating proper flight control system polarity. Demonstration was achieved by stimulating the primary navigation sensor, processing sensor data to commands and viewing propulsion response. PA-1 primary navigation sensor was a Space Integrated Inertial Navigation System (INS) and Global Positioning System (GPS) (SIGI) which has onboard processing, INS (3 accelerometers and 3 rate gyros) and no GPS receiver. SIGI data was processed by GN&C software into thrust magnitude and direction commands. The processing changes through three phases of powered flight: pitchover, downrange and reorientation. The primary inputs to GN&C are attitude position, attitude rates, angle of attack (AOA) and angle of sideslip (AOS). Pitch and yaw attitude and attitude rate responses were verified by using a flight spare SIGI mounted to a 2-axis rate table. AOA and AOS responses were verified by using a data recorded from SIGI movements on a robotic arm located at NASA Johnson Space Center. The data was consolidated and used in an open-loop data input to the SIGI. Propulsion was the Launch Abort System (LAS) Attitude Control Motor (ACM) which consisted of a solid motor with 8 nozzles. Each nozzle has active thrust control by varying throat area with a pintle. LAS ACM pintles are observable through optically transparent nozzle covers. SIGI movements on robot arm, SIGI rate table movements and LAS ACM pintle responses were video recorded as test artifacts for analysis and evaluation. The PA-1 Phasing Test design was determined based on test performance requirements, operational restrictions and EGSE capabilities. This development progressed during different stages. For convenience these development stages are initial, working group, tiger team, Engineering Review Team (ERT) and final.

Neumann, Brian C.↗
DOE OSTI2023

Measurement of needle and armature dynamics in a gasoline direct injector by high-speed neutron imaging

In modern spark ignition engines, precise delivery of fuel with gasoline direct injection has become increasingly important in the effort to meet ever stricter efficiency and emissions regulations. Use of multiple small close-coupled injections has become more common in attempt to precisely control fuel distribution in the cylinder, but these strategies are hindered by nonlinear injection effects due to operation in the ballistic region of the solenoid-operated valve and due to armature bounce at the end of injection. Understanding the internal dynamics of the injector is crucial to minimizing and controlling non-linearity and shot-to-shot variation, but the experimental techniques available to date are capable only of tracking the position of either the top of the needle (via laser sensors or by monitoring current and voltage in the solenoid coil) or the bottom of the needle (via transparent nozzles or high-speed x-ray imaging). Furthermore, a complete picture of the axial and radial motion of valve needle has until now remained elusive. In this work, we present high-speed ensemble neutron transmission imaging of an entire 8-hole gasoline direct injector operating at 200 bar, allowing for both visualization and quantification of the actuation dynamics including lift and wobble of the valve ball, oscillation and bending of the valve needle, lift, rocking, and bounce of the armature, compression of the springs, and radial swelling of the solenoid during energization. Because neutrons offer high penetration through the metal injector while also being sensitive to the 1 H nuclei in fuel molecules, it is also possible to simultaneously see the fluid dynamics of the injection process, including filling of the sac volume, emanation of the spray through the nozzle holes and into the downstream gas, and the formation and evolution of fuel films on the tip of the injector and the walls of the spray container.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1966

Breakup of Droplets in an Accelerating Gas Flow

A study of droplet breakup phenomena by an accelerating gas flow is described. The phenomena are similar to what propellant droplets experience when exposed to accelerating combustion gas flow in a rocket engine combustion zone. Groups of several dozen droplets in the 100-10 750-micron-diameter range were injected into a flowing inert gas in a transparent rectangular nozzle. Motion photography of the behavior of the droplets at various locations in the accelerating gas flow has supplied quantitative and qualitative data on the breakup phenomena which occur under conditions similar to those found in large rocket engine combustors. A blowgun injection device, used to inject very small amounts of liquid at velocities of several hundred feet per second into a moving gas stream, is described. The injection device was used to inject small amounts of liquid RP-1 and water into the gas stream at a velocity essentially equal to the gas velocity where the group of droplets was allowed to stabilize its formation in a constant area section before entering the convergent section of the transparent nozzle. Favorable comparison with the work of previous investigators who have used nonaccelerating gas flow is found with the data obtained from this study with accelerating gas flow. The criterion for the conditions of minimum severity required to produce shear-type droplet breakup in an accelerating gas flow is found to agree well with the criterion previously established at Rocketdyne for breakup in nonaccelerating flow. An extension of the theory of capillary surface wave effects during droplet breakup is also presented. Capillary surface waves propagating in the surface of the droplet, according to classical hydrodynamical laws, are considered. The waves propagate tangentially over the surface of the droplet from the forward stagnation point to the major diameter. Consideration of the effects of relative gas velocity on the amplitude growth of these waves allows conclusions to be made regarding rates of the droplet breakup processes and total time of the breakup process.

Dickerson, R. A.↗
NASA NTRS2009

Wind Tunnel Model Design for the Study of Plume Effects on Sonic Boom for Isolated Exhaust Nozzles

A low cost test capability was developed at the NASA Glenn Research Center 1- by 1-Foot Supersonic Wind Tunnel (SWT), with a goal to reduce the disturbance caused by supersonic aircraft flight over populated areas. This work focused on the shock wave structure caused by the exhaust nozzle plume. Analysis and design was performed on a new rig to test exhaust nozzle plume effects on sonic boom signature. Test capability included a baseline nozzle test article and a wind tunnel model consisting of a strut, a nose cone and an upper plenum. Analysis was performed on the external and internal aerodynamic configuration, including the shock reflections from the wind tunnel walls caused by the presence of the model nosecone. This wind tunnel model was designed to operate from Mach 1.4 to Mach 3.0 with nozzle pressure ratios from 6 to 12 and altitudes from 30,000 ft (4.36 psia) to 50,000 ft (1.68 psia). The model design was based on a 1 in. outer diameter, was 9 in. in overall length, and was mounted in the wind tunnel on a 3/8 in. wide support strut. For test conditions at 50,000 ft the strut was built to supply 90 psia of pressure, and to achieve 20 psia at the nozzle inlet with a maximum nozzle pressure of 52 psia. Instrumentation was developed to measure nozzle pressure ratio, and an external static pressure probe was designed to survey near field static pressure profiles at one nozzle diameter above the rig centerline. Model layout placed test nozzles between two transparent sidewalls in the 1x1 SWT for Schlieren photography and comparison to CFD analysis.

Castner, Raymond S.↗
NASA NTRS2010

Wind Tunnel Model Design for the Study of Plume Effects on Sonic Boom for Isolated Exhaust Nozzles

A low cost test capability was developed at the NASA Glenn Research Center 1- by 1-Foot Supersonic Wind Tunnel (SWT), with a goal to reduce the disturbance caused by supersonic aircraft flight over populated areas. This work focused on the shock wave structure caused by the exhaust nozzle plume. Analysis and design was performed on a new rig to test exhaust nozzle plume effects on sonic boom signature. Test capability included a baseline nozzle test article and a wind tunnel model consisting of a strut, a nosecone and an upper plenum. Analysis was performed on the external and internal aerodynamic configuration, including the shock reflections from the wind tunnel walls caused by the presence of the model nosecone. This wind tunnel model was designed to operate from Mach 1.4 to Mach 3.0 with nozzle pressure ratios from 6 to 12 and altitudes from 30,000 ft (4.36 psia) to 50,000 ft (1.68 psia). The model design was based on a 1 in. outer diameter, was 9 in. in overall length, and was mounted in the wind tunnel on a 3/8 in. wide support strut. For test conditions at 50,000 ft the strut was built to supply 90 psia of pressure, and to achieve 20 psia at the nozzle inlet with a maximum nozzle pressure of 52 psia. Instrumentation was developed to measure nozzle pressure ratio, and an external static pressure probe was designed to survey near field static pressure profiles at one nozzle diameter above the rig centerline. Model layout placed test nozzles between two transparent sidewalls in the 1 1 SWT for Schlieren photography and comparison to CFD analysis.

Castner, Raynold S.↗
DOE OSTI2021

Flow visualisation in real-size optical injectors of conventional, additised, and renewable gasoline blends

Research on renewable and alternative fuels is crucial for improving the energy and environmental efficiency of modern gasoline internal combustion engines. To highlight the influence of fuel rheological and thermodynamic properties on phase change and atomisation processes, three types of gasoline blends were tested. More specifically, the campaign comprised a reference gasoline, an ethanol/gasoline blend (10% v/v) representative of renewable fuels, and an additised gasoline sample treated with viscoelasticity-inducing agents. High-speed imaging of the transient two-phase flow field arising in the internal geometry and the near-nozzle spray region of gasoline injectors was performed employing Diffuse Backlight Illumination. The metallic body of a commercial injector was modified to fit transparent tips realising two nozzle layouts, namely a two-hole real size model resembling the Engine Combustion Network spray G injector and an enraged replica with an offset hole. Experiments were conducted at realistic operating conditions comprising an injection pressure of 100 bar and ambient pressures in the range of 0.1–6.0 bar to cover the entire range of chamber pressures prevailing in Gasoline Direct Injection engines. The action of viscoelastic additives was verified to have a suppressive effect on in-nozzle cavitation (6% reduction in cavitation extent) , while also enhancing spray atomisation at flash-boing conditions, in a manner resembling the more volatile gasoline/ethanol blends. Finally, persisting liquid ligaments were found to form after the end of injection for the additised sample, owing to the surfactant nature of the additives.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

3D printing of void-free glass monoliths: rheological and geometric considerations

Direct ink writing (DIW) is a versatile additive manufacturing technique capable of printing 3D architectures from a broad range of materials. The key advantage of DIW is the ability to spatially control both the architecture and the composition of the printed part, which enables the production of components with previously unachievable combinations of functionalities. One emergent application space for DIW has been in additively manufactured glass optics, where a “green body” is patterned layer-by-layer by extruding a silica-based slurry through a microfluidic nozzle and then thermally consolidated to transparent glass. A critical aspect of the process is ensuring that the printed part is completely free of voids that can occur in the interstitial spaces between the extruded filaments. This outcome is governed by the interplay between ink rheology and strains imposed by the printing process and geometric packing of the filaments. Here, we explore the strain- and rate-dependent deformation events in the DIW process to determine conditions that enable the printing of void-free monoliths without sacrificing shape fidelity. We focus on yield stress fluids consisting of fumed silica nanoparticles dispersed in organic solvents at varied volume fractions to control the rheological properties. We investigate the printability of these ink materials as a function of print process variables and devise the appropriate dimensionless parameters that capture the geometry-dependent and rate-dependent effects on the deformation of the extruded ink. Lastly, we use these scaling arguments to construct a phase diagram for void-free monolith printability.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Plasma arc welding weld imaging

A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.

Rybicki, Daniel J.↗
NASA NTRS1991

Portable Water-Saving Shower For Emergencies

Stowable compact unit sprays from many directions. Proposed portable emergency fogging shower rinses harmful chemicals from person. Includes double-walled transparent, approximately cylindrical curtain containing sets of interior nozzles on regularly spaced loops. Sealed at top and bottom. Victim of contamination enters through longitudinal zippered opening. Pressurized mixture of air and water flows through selected nozzles, creating foglike spray scrubbing contaminants from skin and clothing. Intended for use on Space Station, also used in laboratories and factories on Earth, or for routine shower bathing in areas with limited water supplies.

Grenier, Francis E.↗
NASA NTRS1991

Nuclear light bulb

The nuclear light bulb engine is a closed cycle concept. The nuclear light bulb concept provides containment by keeping the nuclear fuel fluid mechanically suspended in a cylindrical geometry. Thermal heat passes through an internally cooled, fused-silica, transparent wall and heats hydrogen propellant. The seeded hydrogen propellant absorbs radiant energy and is expanded through a nozzle. Internal moderation was used in the configuration which resulted in a reduced critical density requirement. This result was supported by criticality experiments. A reference engine was designed that had seven cells and was sized to fit in what was then predicted to be the shuttle bay mass and volume limitations. There were studies done of nozzle throat cooling schemes to remove the radiant heat. Elements of the nuclear light bulb program included closed loop critical assembly tests done at Los Alamos with UF6 confined by argon buffer gas. It was shown that the fuel region could be seeded with constituents that would block UV radiation from the uranium plasma. A combination of calculations and experiments showed that internal moderation produced a critical mass reduction. Other aspects of the research are presented.

Latham, Tom↗
NASA NTRS2010

Phased Array Noise Source Localization Measurements Made on a Williams International FJ44 Engine

A 48-microphone planar phased array system was used to acquire noise source localization data on a full-scale Williams International FJ44 turbofan engine. Data were acquired with the array at three different locations relative to the engine, two on the side and one in front of the engine. At the two side locations the planar microphone array was parallel to the engine centerline; at the front location the array was perpendicular to the engine centerline. At each of the three locations, data were acquired at eleven different engine operating conditions ranging from engine idle to maximum (take off) speed. Data obtained with the array off to the side of the engine were spatially filtered to separate the inlet and nozzle noise. Tones occurring in the inlet and nozzle spectra were traced to the low and high speed spools within the engine. The phased array data indicate that the Inflow Control Device (ICD) used during this test was not acoustically transparent; instead, some of the noise emanating from the inlet reflected off of the inlet lip of the ICD. This reflection is a source of error for far field noise measurements made during the test. The data also indicate that a total temperature rake in the inlet of the engine is a source of fan noise.

Podboy, Gary G.↗
NASA NTRS1987

A review of research and development on the microwave-plasma electrothermal rocket

The microwave-plasma electrothermal rocket (MWPETR) shows promise for spacecraft propulsion and maneuvering, without some of the drawbacks of competitive electric propulsion systems. In the MWPETR, the electric power is first converted to microwave-frequency radiation. In a specially-designed microwave cavity system, the electromagnetic energy of the radiation is transferred to the electrons in a plasma sustained in the working fluid. The resulting high-energy electrons transfer their energy to the atoms and molecules of the working fluid by collisions. The working fluid, thus heated, expands through a nozzle to generate thrust. In the MWPETR, no electrodes are in contact with the working fluid, the energy is transferred into the working fluid by nonthermal mechanisms, and the main requirement for the materials of construction is that the walls of the plasma chamber be insulating and transparent to microwave radiation at operating conditions. In this survey of work on the MWPETR, several experimental configurations are described and compared. Diagnostic methods used in the study are described and compared, including titration, spectroscopy, calorimetry, electric field measurements, gas-dynamic methods, and thrust measurements. Measured and estimated performance efficiencies are reported. Results of computer modeling of the plasma and of the gas flowing from the plasma are summarized.

Hawley, Martin C.↗
NASA NTRS2006

Microspheres in Plasma Display Panels

Filling small bubbles of molten glass with gases is just as difficult as it sounds, but the technical staff at NASA is not known to shy away from a difficult task. When Microsphere Systems, Inc. (MSI), of Ypsilanti, Michigan, and Imaging Systems Technology, Inc. (IST), of Toledo, Ohio, were trying to push the limits of plasma displays but were having difficulty with the designs, NASA s Glenn Garrett Morgan Commercialization Initiative (GMCI) assembled key personnel at Glenn Research Center and Ohio State University for a brainstorming session to come up with a solution for the companies. They needed a system that could produce hollow, glass micro-sized spheres (microspheres) that could be filled with a variety of gasses. But the extremely high temperature required to force the micro-sized glass bubbles to form at the tip of a metal nozzle resulted in severe discoloration of the microspheres. After countless experiments on various glass-metal combinations, they had turned to the GMCI for help. NASA experts in advanced metals, ceramics, and glass concluded that a new design approach was necessary. The team determined that what was needed was a phosphate glass composition that would remain transparent, and they went to work on a solution. Six weeks later, using the design tips from the NASA team, Tim Henderson, president of MSI, had designed a new system in which all surfaces in contact with the molten glass would be ceramic instead of metal. Meanwhile, IST was able to complete a Phase I Small Business Innovation Research (SBIR) grant supported by the National Science Foundation (NSF) and supply a potential customer with samples of the microspheres for evaluation as filler materials for high-performance insulations.

Source record↗