Engineering topics
Turner, James E.
Publications and source records attributed to Turner, James E..
The Quest for Engineering Innovation at NASA's Marshall Space Flight (MSFC)
A recent NASA team, chartered to examine innovation within the Agency, captured the meaning of the word innovation as the "application of creative ideas to improve and generate value for the organization". The former NASA Administrator Charles Bolden shared his own thoughts about innovation in a memo with all employees that stated, "At NASA, we are dedicated to innovation, bold ideas, and excellence." Innovation turns out to be one of the major driving forces behind the work produced at NASA. It seems failure is often what has driven NASA to be more innovative. Fifty years ago, the Apollo 1 tragedy killed three astronauts when fire erupted in their command module. NASA had to bear the responsibility of such loss and at the same time work smarter in order to obtain the dream to reach the moon by the end of the 1960s. Through this circumstance, NASA engineers developed a revolutionary replacement for the combustible nylon astronaut suits so the Apollo program could continue. A material called Beta Cloth was born. This material was used to produce noncombustible space suits for all Apollo astronauts, enabling the United States to ultimately land 12 Americans on the moon. Eventually this material was used as the roof system in the Denver International Airport, showing relevance and applications of NASA innovations to real-world need. Innovative ideas are also driven by the need to accomplish NASA missions and to improve the way we produce our products. MSFC engineers are advancing technologies in additive manufacturing of liquid rocket engines in order to reduce the number of parts, design time, and the cost of the engines. NASA is working with academia to eliminate the need for miles of sensor cables by investigating innovations in wireless sensors. In order to enable future exploration missions to Mars, MSFC engineers are pursuing innovative approaches in diverse areas such as the use of ionic liquids for life support systems and composite cryogenic tanks, very low leakage valves to contain propulsion fluids, and natural, non-toxic inhibitors to eliminate the buildup of biofilms in the water systems planned for future crewed Mars missions. Although results are encouraging, we cannot rest on our past accomplishments. In order to overcome breathtaking technical challenges in space exploration, we must continue to promote a culture supporting growth, breakthroughs and disruptive innovations.
Steady and Unsteady Simulations of the Flow in an Impeller/Diffuser Stage
SLI engine designs will require pumps to throttle over a wide flow range while maintaining high performance. Unsteadiness generated by impeller/diffuser interaction is one of the major factors affecting off-design performance. Initial unsteady simulations are completed for impeller/diffuser stage. The Corsair simulations will continue across a wide flow range and for inducer/impeller/diffuser combinations. Results of unsteady simulations are being used to guide and explore new designs.
MSFC Turbine Performance Optimization (TPO) Technology Verification Status
Capability to optimize for turbine performance and accurately predict unsteady loads will allow for increased reliability, Isp, and thrust-to-weight. The development of a fast, accurate, validated aerodynamic design, analysis, and optimization system is required.
Rocket Engine Oscillation Diagnostics
Rocket engine oscillating data can reveal many physical phenomena ranging from unsteady flow and acoustics to rotordynamics and structural dynamics. Because of this, engine diagnostics based on oscillation data should employ both signal analysis and physical modeling. This paper describes an approach to rocket engine oscillation diagnostics, types of problems encountered, and example problems solved. Determination of design guidelines and environments (or loads) from oscillating phenomena is required during initial stages of rocket engine design, while the additional tasks of health monitoring, incipient failure detection, and anomaly diagnostics occur during engine development and operation. Oscillations in rocket engines are typically related to flow driven acoustics, flow excited structures, or rotational forces. Additional sources of oscillatory energy are combustion and cavitation. Included in the example problems is a sampling of signal analysis tools employed in diagnostics. The rocket engine hardware includes combustion devices, valves, turbopumps, and ducts. Simple models of an oscillating fluid system or structure can be constructed to estimate pertinent dynamic parameters governing the unsteady behavior of engine systems or components. In the example problems it is shown that simple physical modeling when combined with signal analysis can be successfully employed to diagnose complex rocket engine oscillatory phenomena.
Prediction of Drag Reduction in Supersonic and Hypersonic Flows with Counterflow Jets
Computational fluid dynamics solutions of the flowfield of a truncated cone-cylinder with and without counterflow jets have been obtained for the short penetration mode (SPM) and long penetration mode (LPM) of the freestream-counterflow jet interaction flowfield. For the case without the counterflow jet, the comparison of the normalized surface pressures showed very good agreement with experimental data. For the case with the SPM jet, the predicted surface pressures did not compare as well with the experimental data upstream of the expansion corner, while aft of the expansion corner, the comparison of the solution and the data is seen to give much better agreement. The difference in the prediction and the data could be due to the transient character of the jet penetration modes, possible effects of the plasma physics that are not accounted for here, or even the less likely effect of flow turbulence, etc. For the LPM jet computations, one-dimensional isentropic relations were used to derived the jet exit conditions in order to obtain the LPM solutions. The solution for the jet exit Mach number of 3 shows a jet penetration several times longer than that of the SPM, and therefore much weaker bow shock, with an attendant reduction in wave drag. The LPM jet is, in essence, seen to be a "pencil" of fluid, with much higher dynamic pressure, embedded in the oncoming supersonic or hypersonic freestream. The methodology for determining the conditions for the LPM jet could enable a practical approach for the design and application of counterflow LPM jets for the reduction of wave drag and heat flux, thus significantly enhancing the aerodynamic characteristics and aerothermal performance of supersonic and hypersonic vehicles. The solutions show that the qualitative flow structure is very well captured. The obtained results, therefore, suggest that counterflowing jets are viable candidate technology concepts that can be employed to give significant reductions in wave drag, heat flux, and other attendant aerodynamic benefits.
Microgravity Propellant Tank Geyser Analysis and Prediction
An established correlation for geyser height prediction of an axial jet inflow into a microgravity propellant tank was analyzed and an effort to develop an improved correlation was made. The original correlation, developed using data from ethanol flow in small-scale drop tower tests, uses the jet-Weber number and the jet-Bond number to predict geyser height. A new correlation was developed from the same set of experimental data using the jet-Weber number and both the jet-Bond number and tank-Bond number to describe the geyser formation. The resulting correlation produced nearly a 40% reduction in geyser height predictive error compared to the original correlation with experimental data. Two additional tanks were computationally modeled in addition to the small-scale tank used in the drop tower testing. One of these tanks was a 50% enlarged small-scale tank and the other a full-scale 2 m radius tank. Simulations were also run for liquid oxygen and liquid hydrogen. Results indicated that the new correlation outperformed the original correlation in geyser height prediction under most circumstances. The new correlation has also shown a superior ability to recognize the difference between flow patterns II (geyser formation only) and III (pooling at opposite end of tank from the bulk fluid region).
Transition of a Three-Dimensional Unsteady Viscous Flow Analysis from a Research Environment to the Design Environment
The advent of advanced computer architectures and parallel computing have led to a revolutionary change in the design process for turbomachinery components. Two- and three-dimensional steady-state computational flow procedures are now routinely used in the early stages of design. Unsteady flow analyses, however, are just beginning to be incorporated into design systems. This paper outlines the transition of a three-dimensional unsteady viscous flow analysis from the research environment into the design environment. The test case used to demonstrate the analysis is the full turbine system (high-pressure turbine, inter-turbine duct and low-pressure turbine) from an advanced turboprop engine.
Lightweight Chambers for Thrust Assemblies
The Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) has successfully applied new materials and fabrication techniques to create actively cooled thrust chambers that operate 200-400 degrees hotter and weigh 50% lighter than conventional designs. In some vehicles, thrust assemblies account for as much as 20% of the engine weight. So, reducing the weight of these components and increasing their operating range will benefit many engines and vehicle designs, including Reusable Launch Vehicle (RLV) concepts. Obviously, copper and steel alloys have been used successfully for many years in the chamber components of thrust assemblies. Yet, by replacing the steel alloys with Polymer Matrix Composite (PMC) and/or Metal Matrix Composite (MMC) materials, design weights can be drastically reduced. In addition, replacing the traditional copper alloys with a Ceramic Matrix Composite (CMC) or an advanced copper alloy (Cu-8Cr-4Nb, also known as GRCop-84) significantly increases allowable operating temperatures. Several small MMC and PMC demonstration chambers have recently been fabricated with promising results. Each of these designs included GRCop-84 for the cooled chamber liner. These units successfully verified that designs over 50% lighter are feasible. New fabrication processes, including advanced casting technology and a low cost vacuum plasma spray (VPS) process, were also demonstrated with these units. Hot-fire testing at MSFC is currently being conducted on the chambers to verify increased operating temperatures available with the GRCop-84 liner. Unique CMC chamber liners were also successfully fabricated and prepared for hot-fire testing. Yet, early results indicate these CMC liners need significantly more development in order to use them in required chamber designs. Based on the successful efforts with the MMC and PMC concepts, two full size "lightweight" chambers are currently being designed and fabricated for hot-fire testing at MSFC in 2001. These "full size" chambers will be similar in size to those used on the X33 engine (RS2200). One will be fabricated with a MMC structural jacket, while the other uses a PMC jacket. Each will be designed for thrust levels of 15,000 pounds in an oxygen/hydrogen environment with liquid hydrogen coolant. Both chambers will use GRCop-84 for its channel wall liner. Each unit is expected to be at least 60% lighter than a conventional design with traditional materials. Hot-fire testing on the full size units in late 2001 will directly compare performance results between a conventional chamber design and these "lightweight" alternatives. The technology developed and demonstrated by this effort will not only benefit next generation RLV programs, but it can be applied to other existing and future engine programs, as well. Efforts were sponsored by the Advanced Space Transportation Program for RLV Focused Technologies. The task team was led by MSFC with additional members from NASA-Glenn Research Center and the Rocketdyne Division of The Boeing Company. Specific materials development and fabrication processes were provided by Aerojet, Lockheed Martin Astronautics, Composite Optics, Inc., Hyper-Therm, Ceramic Composites, Inc., MSE Technology Applications, and Plasma Processes, Inc.
Rocket Engine Turbine On-Blade Fluctuating Pressure Experimental work
Contents of the Fluids Workshop include: Background; SSME HPFT On-Blade Effort; and Turbine Performance Optimization Effort.
Turbine Performance Optimization Task Status
Capability to optimize for turbine performance and accurately predict unsteady loads will allow for increased reliability, Isp, and thrust-to-weight. The development of a fast, accurate aerodynamic design, analysis, and optimization system is required.
Unic Unstructured CFD Methodology Development
Base heating characteristics is crucial to the success and the overall performance of the X-33 engine. Base heating is important throughout the entire flight trajectory due to the aerospike engine design of X-33. The base region is surrounded by the hot-gas plume, which expands, circulates and impinges on the base. An advanced computation fluid dynamics method is employed in an effort to develop a robust, accurate and efficient tool for the X-33 base heating performance predictions. This computational tool is developed based on a Navier-Stokes flow solver, which is suitable for general complex geometry and includes turbulence, finite-rate chemistry, and radiation models. To fulfill the fast turnaround requirement as a design analysis tool, adaptive mesh refinement method and parallel-computing algorithm are also incorporated in the present model. Case study for the X-33 base-region fluid dynamics and heat transfer characteristics are presented.
Simplex Turbine Full and Partial Admission Performance
This report analyzes the full and partial admission simulation for the simplex turbine.
Numerical Investigation of Radiative Heat Transfer in Laser Induced Air Plasmas
Radiative heat transfer is one of the most important phenomena in the laser induced plasmas. This study is intended to develop accurate and efficient methods for predicting laser radiation absorption and plasma radiative heat transfer, and investigate the plasma radiation effects in laser propelled vehicles. To model laser radiation absorption, a ray tracing method along with the Beer's law is adopted. To solve the radiative transfer equation in the air plasmas, the discrete transfer method (DTM) is selected and explained. The air plasma radiative properties are predicted by the LORAN code. To validate the present nonequilibrium radiation model, several benchmark problems are examined and the present results are found to match the available solutions. To investigate the effects of plasma radiation in laser propelled vehicles, the present radiation code is coupled into a plasma aerodynamics code and a selected problem is considered. Comparisons of results at different cases show that plasma radiation plays a role of cooling plasma and it lowers the plasma temperature by about 10%. This change in temperature also results in a reduction of the coupling coefficient by about 10-20%. The present study indicates that plasma radiation modeling is very important for accurate modeling of aerodynamics in a laser propelled vehicle.
Unshrouded Impeller Technology Task Status
The objective of this presentation is to develop an unshrouded impeller design that will meet the performance requirements of a 3-stage fuel pump with a 2-stage pump design.
Turbine Aerodynamics Design Tool Development
This paper presents the Marshal Space Flight Center Fluids Workshop on Turbine Aerodynamic design tool development. The topics include: (1) Meanline Design/Off-design Analysis; and (2) Airfoil Contour Generation and Analysis. This paper is in viewgraph form.
Overview of MSFC's Applied Fluid Dynamics Analysis Group Activities
This document is a presentation graphic which reviews the activities of the Applied Fluid Dynamics Analysis Group at Marshall Space Flight Center (i.e., Code TD64). The work of this group focused on supporting the space transportation programs. The work of the group is in Computational Fluid Dynamic tool development. This development is driven by hardware design needs. The major applications for the design and analysis tools are: turbines, pumps, propulsion-to-airframe integration, and combustion devices.
Global Optimization Techniques for Fluid Flow and Propulsion Devices
This viewgraph presentation gives an overview of global optimization techniques for fluid flow and propulsion devices. Details are given on the need, characteristics, and techniques for global optimization. The techniques include response surface methodology (RSM), neural networks and back-propagation neural networks, design of experiments, face centered composite design (FCCD), orthogonal arrays, outlier analysis, and design optimization.