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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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Fuel Heating System Design and Thermal Modeling for Aviation Combustion Research

Aviation fuels offer substantial heat-sink capability that can be applied to aircraft thermal-management strategies and advanced propulsion-system concepts. Accurate control of fuel temperature is critical for understanding combustion behavior and supporting high temperature fuel experimental studies. This work describes the modeling and experimental validation of a portable, high temperature fuel-conditioning system designed for multiple NASA Glenn Research Center’s combustion facilities. The system utilizes a circulating-oil heating unit and modular tube-in-tube heat exchangers capable of conditioning Jet-A to temperatures approaching 600 K. A Thermal Desktop model was created to analyze heat exchanger configurations and predict performance across a range of operating conditions. Model predictions were compared with measurements collected in the CE-13C test facility, showing good agreement across the tested flow range except at low fuel flow rate around 2 kg/hr. Results provide guidance for sizing future fuel heating system for combustion research applications.

Jet fuel heating system

Combustor Technology for Future Small Gas Turbine Aircraft

To enhance fuel efficiency, future advanced small gas turbine engines will utilize engine cycles calling for overall engine pressure ratios, leading to higher combustor inlet pressures and temperatures. Further, the temperature rise through the combustor and the corresponding exit temperature are also expected to increase. This report describes future combustor technology needs for small gas turbine engines. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is anticipated in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors. Due to combustor size considerations, staged combustion is more easily accommodated in large engines. The inclusion of staged combustion in small engines will pose greater combustor design challenges.

Valerie J Lyons

Assessment of Aircraft Electric Engine Regulatory Special Conditions

This report provides a regulatory gap assessment of the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA) Special Conditions (SC) for electric engines. This information is presented to support ongoing international harmonization efforts for electric engine certification, to establish a level of safety consistent across regulatory bodies and equivalent to that of existing combustion engines. HS Advanced Concepts LLC assembled a team of subject-matter experts to develop a comprehensive comparison of the regulatory text of EASA SC E-19 and the FAA special conditions for the certification of electric engines. The team included Mr. Chris Baczynski of BAC Aerospace Inc. and Mr. Zach Kaufman, formerly with magniX.

aircraft certification

Preliminary Dynamic Modeling of the Quarter-Scale Distributed Electric Propulsion Aircraft

This paper describes the early-stage modeling of a quarter-scale distributed electric propulsion aircraft, based on the SUbsonic Single Aft eNgine (SUSAN) Electrofan, a transformative concept aircraft for which a model exists. The full-scale 180 passenger SUSAN concept has a single turbofan engine in the tail that both produces thrust and provides electrical power to 16 electric fans distributed across the wings utilizing a series/parallel hybrid architecture. The quarter-scale version would have an internal combustion piston engine to provide power to 17 electric fans–16 on the wings, one in the tail–in a series hybrid configuration, and no vertical or horizontal stabilizers. It would also have a reduced flight envelope in terms of both altitude and speed. The initial modeling approach is to scale down the original airframe model to capture the dynamic behavior of a much smaller aircraft, albeit with an empennage. The original powertrain model is then replaced with one representing the physical components of that of the quarter-scale vehicle. This powertrain model is suitable for control design and analysis, and the fully integrated, although preliminary, aircraft model allows flight simulator testing and evaluation. Results from simulations are presented.

electrified aircraft propulsion

Preliminary Dynamic Modeling of the Quarter-Scale Distributed Electric Propulsion Aircraft

This presentation describes the early-stage modeling of a quarter-scale distributed electric propulsion aircraft, based on the SUbsonic Single Aft eNgine (SUSAN) Electrofan, a transformative concept aircraft for which a model exists. The full-scale 180 passenger SUSAN concept has a single turbofan engine in the tail that both produces thrust and provides electrical power to 16 electric fans distributed across the wings utilizing a series/parallel hybrid architecture. The quarter-scale version would have an internal combustion piston engine to provide power to 17 electric fans–16 on the wings, one in the tail–in a series hybrid configuration, and no vertical or horizontal stabilizers. It would also have a reduced flight envelope in terms of both altitude and speed. The initial modeling approach is to scale down the original airframe model to capture the dynamic behavior of a much smaller aircraft, albeit with an empennage. The original powertrain model is then replaced with one representing the physical components of that of the quarter-scale vehicle. This powertrain model is suitable for control design and analysis, and the fully integrated, although preliminary, aircraft model allows flight simulator testing and evaluation. Results from simulations are presented.

electrified aircraft propulsion

Preliminary Dynamic Modeling of the Quarter-Scale Distributed Electric Propulsion Aircraft

This paper describes the early-stage modeling of a quarter-scale distributed electric propulsion aircraft, based on the SUbsonic Single Aft eNgine (SUSAN) Electrofan, a transformative concept aircraft for which a model exists. The full-scale 180 passenger SUSAN concept has a single turbofan engine in the tail that both produces thrust and provides electrical power to 16 electric fans distributed across the wings utilizing a series/parallel hybrid architecture. The quarter-scale version would have an internal combustion piston engine to provide power to 17 electric fans–16 on the wings, one in the tail–in a series hybrid configuration, and no vertical or horizontal stabilizers. It would also have a reduced flight envelope in terms of both altitude and speed. The initial modeling approach is to scale down the original airframe model to capture the dynamic behavior of a much smaller aircraft, albeit with an empennage. The original powertrain model is then replaced with one representing the physical components of that of the quarter-scale vehicle. This powertrain model is suitable for control design and analysis, and the fully integrated, although preliminary, aircraft model allows flight simulator testing and evaluation. Results from simulations are presented.

Electrified powertrain

Atmospheric, Non-Combusting Droplet Sizing and Spray Imaging Results From a Non-Proprietary Aero Gas Turbine Engine Pressure Swirl Atomizer using Shadowgraphy and Planar Laser Scatter

Members from industry and federal agencies of the United States have developed a collaborating group focused on improving the understanding of the atomization processes common to gas turbine engines. The group is aimed on providing high quality data using x-ray diagnostics in the internal geometry and the near-field dense spray as well as optical diagnostics in the visible spectrum, downstream of the nozzle. This paper reports results from one of the two non-proprietary injectors designs from the group: the primary-secondary injector. In particular, we characterize the spray from only the primary, pressure-swirl atomizing circuit using water through the nozzle. We observed Sauter mean diameter decreased with increased water pressure drop across the nozzle. SMD was also collected at three axial distances and showed decreased size with distance from the nozzle. Planar laser sheet droplet scattering provided qualitative assessment of the spray. Higher water pressure drops provided better atomization than lower pressure drops. The addition of swirling air flow through the injector alleviates and improves the atomization quality, particularly at the lower water pressure drops.

optical diagnostics

Spray Combustion Stability

The central purpose of this project is the improvement of liquid-fueled rocket motor design technology in order to assist the establishment of economical commercial access to space through the development of engines with enhanced performance and reliability. Specific research effort is focused on spray physics and associated combustion instability phenomena. Results concerning high pressure droplet gasification model, droplet turbulent dispersion model, and spray atomization model will contribute to the development of new computational tools for design of stable liquid propellant rocket engines.

Pak-Yan Liang

Advanced Non-Intrusive Instrumentation for Propulsion Engines

Changes in engine technology such as higher temperatures, higher tip speeds, new metal/composite/ceramic materials together with radical changes in design philosophy will require amongst other prerequisites the ability to measure and to monitor key internal gas and structural characteristics. The symposium papers presented non-intrusive measurement and analysis technologies in the following categories: Laser Point Measurements (11); Absorption and Infrared Techniques (4); Paints - Surface Sensors (6); Laser Induced Fluorescence (6); Mechanical (7); Films (5); Laser Planar Measurement (9); and a Keynote Address.

Propulsion

Evaluation of Particle Degradation of a Ytterbium Disilicate Gas Turbine Coating in a Combustion Environment

Ytterbium disilicate (Yb2Si2O7) is a state-of-the-art topcoat material used in environmental barrier coatings (EBCs) to protect SiC-SiC composites from water vapor corrosion in gas turbine engines. However, it’s degradation by thermochemical and thermomechanical particle interactions may limit its use in next generation engine systems. Several static furnace tests have been performed on Yb2Si2O7 to elucidate methods of degradation, although dynamic testing in an engine-relevant environment has not been carried out. Ultimately, testing and evaluation of materials that incorporates all environmental damage modes will allow for an accurate assessment of long-term durability and operating lifetime. This work details the investigation of particle-induced erosion and corrosion of Yb2Si2O7 in NASA Glenn’s Erosion Burner Rig Facility. Coating durability was investigated as a function of test temperature, particle size, and deposition rate. Thermal cycling was also incorporated into testing to determine the interplay of heating/cooling cycles with particle degradation. Overall, these analyses will be used to determine coating robustness in an engine relevant environment.

Jamesa L Stokes

Overview of initial research into the effects of strong vortex flow on hybrid rocket combustion and performance

An examination of the effect of vortex flow on hybrid rocket combustion and performance is underway. Emphasis is on response of the fuel regression rate when subjected to vortex flow. Initial results show that there is a definite effect of the vortex on fuel regression rate. Future work will focus on quantitatively measuring this regression rate. This work is part of an overall program to develop an ultra low cost fuel system for hybrid rocket engines.

P Gloyer

Controls for Electrified Aircraft Propulsion

Advanced electrified aircraft propulsion (EAP) concepts with integrated power, propulsion, and thermal systems require the development of equally sophisticated controllers to fly safe and efficient missions. Hybrid electric aircraft utilize electric machines mechanically coupled to the engine shafts to extract and insert power for a variety of purposes. Additionally, electric machines may drive propulsive fans pulling from a combination of on-board energy storage devices and engine extracted power. NASA’s investment in hybrid electric aircraft hardware-in-the-loop testing enables controls research on representative engine models using a novel emulation and scaling methodology. High-voltage, high-power electrical powertrain presents several technical risks at altitude. High-power requires high efficiency to minimize losses. Superconducting electric machines and power distribution research at NASA has identified key challenges with potential controls solutions. These risks necessitate the development of controllers robust to model uncertainty, disturbances, and fault conditions. System health management and fault detection schemes play an important role in a multi-layer controls approach that utilizes a supervisor which oversees inner loops for the highly coupled power, propulsion, and thermal systems. Such a supervisory controller enables coordinates energy transfer between engines, energy storage devices, electric machines, propulsors, and heat exchangers. Existing methods have shown an improvement in engine operability using the hybrid electric powertrain.

Halle E Buescher

Cryogenic Fuel Aviation – Challenges and Opportunities

NASA aeronautics goals include pioneering new technology to increase efficiency and reduce emissions from air travel. The feasibility of using of on-board cryogenic fuels systems in combination with fuel cells, high efficiency engines, and electric motors for high efficiency commercial transport aircraft is being examined at NASA in collaborations with external partners. Growing emphasis on next generation air transportation resulted in the development of strategic investigations into cryogenic fuels aviation, including roadmaps for maturing new technologies, needs to improve testing and manufacturing capabilities, and the requirements for establishing regulatory and certification standards. A NASA cross-organizational multidisciplinary project team is exploring new aircraft architectures, enabling materials, and the engineering challenges associated with cryogenic fuels for aircraft. The engineering challenges include high performance cryogenic, thermal management, and power/propulsion components and subsystems to tackle the challenging problem of development of commercially viable aircraft that would radically transform air transportation.

liquid natural gas

Overview 1993: Chemical propulsion at CSTAR

Chemical Propulsion at CSTAR continues to expand its activities and areas of interest. Several new initiatives are being developed which are extensions of, or replacements for, earlier projects. One current focus is on reassessing promising engine cycles and the enabling technologies for implementing them. These engine cycles which include advanced hybrids, and staged combustion cycles have the use of oxygen as a working fluid and coolant in common. Oxygen is used as a turbine drive gas, tank pressurant and as a cooling medium for combustion devices. CSTAR has interest in the propellant feed systems for advanced rocket engines, including propellant conditioning and tank pressurization, gas generators, and turbomachinery. CSTAR's interests also include propellant injection into the main chamber. These aspects of rocket propulsion embody a diverse range of technical disciplines and technologies, critical to the pursuit of low cost space access. The chemical propulsion program at CSTAR includes active projects investigating hybrid rocket engine oxygen feed systems, hybrid rocket injectors, gas fed hybrid rocket combustion, elements of main injectors for staged combustion devices. CSTAR is actively seeking industrial partners interested in joint participation in one or more phases of the analyses, design, development and application of propulsion technologies and related technical disciplines.

William H. Knuth

Future Aerospace Technology in the Service of the Alliance: Sustained Hypersonic Flight - Volume 3

Sustained Hypersonic Flight capability is envisioned for several future military and civilian applications, such as long range immediate reaction reconnaissance, high speed interception of air targets, long range precision strike against hardened or time critical targets, and access to space. The inherent reduction in time-to-target and low vulnerability will permit new operational tactics. The symposium outlined mission needs and operational scenarios for hypersonic vehicles. Addressed were: Technological issues and challenges in external hypersonic aerodynamics and design, propulsion and engine/airframe integration, military ramjet applications, overall system design including structures and materials development needs, and test facilities. Ground based test facilities cannot provide full simulation at Mach numbers above 5. Therefore, the use of Computational Fluid Dynamics design tools is essential. For routine use of the computational tools in analysis, design and optimization, it is necessary to reduce the time for the entire computational process by two orders of magnitude. Hypersonic boundary layer transition remains a critical design issue because of the important impact on engine drag and on heating, which can affect the choice of materials and thermal protection systems. In addition, reliable prediction of scramjet net thrust is an absolute must in resolving hypersonic air breathing vehicle design issues. Due to current facility and computational shortfalls, the development of future hypersonic flight systems requires research flight tests in the technology areas of boundary layer transition and air-breathing propulsion engine performance. For sustained hypersonic flight beyond Mach 6, the supersonic combustion ramjet (scramjet) engine is the only choice for the near future. Only this air-breathing concept offers a significant promise of large reductions in required propellant fractions, increased payload fractions, and reduced size vehicles, together with a foreseeable technological feasibility. Airframe/engine integration, combustor design and thermal management are the predominant engineering tasks. Fuels, hydrogen or hydrocarbon, must be matched to the operational needs of military or civil use. Experience in existing ramjet propelled missiles capable of speeds up to Mach 4 can support the development effort. The potential mission and cost benefits of sustained hypersonic flight to both military and civil applications are tremendous. From the budget point of view, the possibility of sharing development costs between military and civil programs offers a specific advantage.

Combustion chambers

Optimization of a 10–Step Reduced CH₄/O₂ Combustion Mechanism for RDRE Applications

A 10-step, 9-species reduced mechanism for methane/oxygen combustion is evaluated and optimized for use in rotating detonation rocket engine (RDRE) simulations at an operating pressure of 10 bar. The mechanism is assessed against GRI-Mech 3.0 for ignition delay times, adiabatic equilibrium temperature and species, Chapman-Jouguet (CJ) detonation parameters, and laminar flame speed. A sequential Nelder–Mead optimization procedure is applied to the rate constants of reactions R1, R4, and R5, targeting ignition delay agreement over the equivalence ratio range φ = 1.0–1.4 and temperature range T = 1400–2000 K. The optimized mechanism achieves ignition delay agreement within 28% of GRI-Mech 3.0 for the temperature range relevant to RDRE operation (τ ≥ 5 μs). Adiabatic equilibrium temperatures and CJ detonation parameters are reproduced within 0.15% of GRI-Mech 3.0 values, confirming thermodynamic consistency of the mechanism. Laminar flame speed predictions deviate significantly from GRI-Mech 3.0, which is attributed to the absence of HO₂ chemistry in the reduced mechanism; this limitation does not affect RDRE simulation fidelity since laminar flame propagation is of secondary importance in RDREs.

Computational Fluid Dynamics

Updates and Modernization of the Chemical Equilibrium with Applications (CEA) Code

NASA’s Chemical Equilibrium with Applications (CEA) code is a foundational tool for propulsion system analysis. It provides equilibrium chemistry, rocket performance, shock, and detonation calculations used across NASA and the broader aerospace community. NASA Engineering and Safety Center (NESC) Activity TI-22-01730 modernized the legacy CEA2 Fortran code into CEA v3, a Fortran 2008, object-oriented software package with expanded interface support, updated thermochemical data, improved maintainability, and substantially improved workflow integration. The modernized code preserves backward compatibility with legacy CEA input workflows while enabling direct use from modern analysis environments, including Python, C, MATLAB, and automated design studies.

Combustion