Engineering topics

Turner, James E.

Publications and source records attributed to Turner, James E..

At least 37 records · Page 2

NASA NTRS2001

Development and Validation of High Performance Unshrouded Centrifugal Impeller

The feasibility of using a two-stage unshrouded impeller turbopump to replace the current three-stage reusable launch vehicle engine shrouded impeller hydrogen pump has been evaluated from the standpoint of turbopump weight reduction and overall payload improvement. These advantages are a by-product of the higher tip speeds that an unshrouded impeller can sustain. The issues associated with the effect of unshrouded impeller tip clearance on pump efficiency and head have been evaluated with one-dimensional tools and full three-dimensional rotordynamic fluid reaction forces and coefficients have been established through time dependent computational fluid dynamics (CFD) simulation of the whole 360 degree impeller with different rotor eccentricities and whirling ratios. Unlike the shrouded impeller, the unshrouded impeller forces are evaluated as the sum of the pressure forces on the blade and the pressure forces on the hub using the CFD results. The turbopump axial thrust control has been optimized by adjusting the first stage impeller backend wear ring seal diameter and diverting the second stage backend balance piston flow to the proper location. The structural integrity associated with the high tip speed has been checked by analyzing a 3D-Finite Element Model at maximum design conditions (6% higher than the design speed). This impeller was fabricated and tested in the NASA Marshall Space Flight Center water-test rig. The experimental data will be compared with the analytical predictions and presented in another paper. The experimental data provides validation data for the numerical design and analysis methodology. The validated numerical methodology can be used to help design different unshrouded impeller configurations.

Chen, Wei-Chung↗

NASA NTRS2001

Autofrettage to Counteract Coefficient of Thermal Expansion Mismatch in Cryogenic Pressurized Pipes with Metallic Liners

Composite feedlines with metal liners have the potential to reduce weight/cost while providing the same level of permeation resistance and material compatibility of all-metal feedlines carrying cryogenic propellants in spacecraft. The major technical challenges are the large difference in Coefficient of Thermal Expansion between the liner and the composite, and the manufacturing method required to make a very thin liner with the required strength and dimensional tolerance. This study investigates the use of autofrettage (compressive preload) to counteract Coefficient of Thermal Expansion when pre-pressurization procedures cannot be used to solve this problem. Promising materials (aluminum 2219, Inconel 718, nickel, nickel alloy) and manufacturing techniques (chemical milling, electroplating) are evaluated to determine the best liner candidates. Robust, autofrettaged feedlines with a low Coefficient of Thermal Expansion liner (Inconel 718 or nickel alloy) are shown to successfully counteract mismatch at LOX temperature. A new concept, autofrettage by temperature, is introduced for high Coefficient of Thermal Expansion materials (aluminum and pure nickel) where pressure cannot be used to add compressive preload.

Wen, Ed↗

NASA NTRS2001

Analysis of X-33 Linear Aerospike Plume Induced Base-Heating Environment During Power-Pack Out

The objectives of this viewgraph presentation are to predict the following: (1) dual-engine base-heating at 57% PL at sea level, and (2) dual-engine base-heating during PPO at three ascent abort trajectories. A systematically anchored computational fluid dynamics and heat transfer three-dimensional transfer simulation is being used to study the effect of reduced power levels on base-heating environments during sea level testing and during PPO. Preliminary results show the following: (1) convective heating is higher for the 57% PL than for 100% PL on most of the pillows and flex seals during sea level testing; and (2) convective heating on pillows and flex seals on the 'off' engine side is higher than that on the 'on' engine side.

Wang, Ten-See↗

NASA NTRS2000

NASA Fastrac Engine Gas Generator Component Test Program and Results

This presentation consists of viewgraph which review the test program and the results of the tests for the Gas Generator (GG) component for the Fastrac Engine. Included are pictures of the Fastrac (MC-1) Engine and the GG, diagrams of the flight configuration, and schematics of the LOX, and the RP-1 systems and the injector assembly. The normal operating parameters are reviewed, as are the test instrumentation. Also shown are graphs of the hot gas temperature, and the test temperature profiles. The results are summarized.

Dennis, Henry J., Jr.↗

NASA NTRS2000

Blade Surface Pressure Distributions in a Rocket Engine Turbine: Experimental Work With On-Blade Pressure Transducers

Understanding the unsteady aspects of turbine rotor flowfields is critical to successful future turbine designs. A technology program was conducted at NASA's Marshall Space Flight Center to increase the understanding of unsteady environments for rocket engine turbines. The experimental program involved instrumenting turbine rotor blades with surface-mounted high frequency response pressure transducers. The turbine model was then tested to measure the unsteady pressures on the rotor blades. The data obtained from the experimental program is unique in three respects. First, much more unsteady data was obtained (several minutes per set point) than has been possible in the past. Also, two independent unsteady data acquisition systems and fundamental signal processing approaches were used. Finally, an extensive steady performance database existed for the turbine model. This allowed an evaluation of the effect of the on-blade instrumentation on the turbine's performance. This unique data set, the lessons learned for acquiring this type of data, and the improvements made to the data analysis and prediction tools will contribute to future turbine programs such as those for reusable launch vehicles.

Hudson, Susan T.↗

NASA NTRS2000

Low-Cost Approach to the Design and Fabrication of a LOX/RP-1 Injector

NASA Marshall Space Flight Center (MSFC) has designed, built, and is currently testing Fastrac, a liquid oxygen (LOX)/RP-1 fueled 60K-lb thrust class rocket engine. One facet of Fastrac, which makes it unique is that it is the first large-scale engine designed and developed in accordance with the Agency's mandated "faster, better, cheaper" (FBC) program policy. The engine was developed under the auspices of MSFC's Low Cost Boost Technology office. Development work for the main injector actually began in 1993 in subscale form. In 1996, work began on the full-scale unit approximately 1 year prior to initiation of the engine development program. In order to achieve the value goals established by the FBC policy, a review of traditional design practices was necessary. This internal reevaluation would ultimately challenge more conventional methods of material selection. design process, and fabrication techniques. The effort was highly successful. This "new way" of thinking has resulted in an innovative injector design, one with reduced complexity and significantly lower cost. Application of lessons learned during this effort to new or existing designs can have a similar effect on costs and future program successes.

Shadoan, Michael D.↗

NASA NTRS2000

Development Status of the NASA MC-1 (Fastrac) Engine

The MC-1 (formerly known as the Fastrac 60K) Engine is being developed for the X-34 technology demonstrator vehicle. It is a pump-fed liquid rocket engine with fixed thrust operating at one rated power level of 60,000 lbf vacuum thrust using a 15:1 area ratio nozzle (slightly higher for the 30:1 flight nozzle). Engine system development testing of the MC-1 has been ongoing since 24 Oct 1998. To date, 48 tests have been conducted on three engines using three separate test stands. This paper will provide some details of the engine, the tests conducted, and the lessons learned to date.

Ballard, Richard O.↗

NASA NTRS2000

Advanced Engine Health Management Applications of the SSME Real-Time Vibration Monitoring System

The Real Time Vibration Monitoring System (RTVMS) is a 32-channel high speed vibration data acquisition and processing system developed at Marshall Space Flight Center (MSFC). It Delivers sample rates as high as 51,200 samples/second per channel and performs Fast Fourier Transform (FFT) processing via on-board digital signal processing (DSP) chips in a real-time format. Advanced engine health assessment is achieved by utilizing the vibration spectra to provide accurate sensor validation and enhanced engine vibration redlines. Discrete spectral signatures (such as synchronous) that are indicators of imminent failure can be assessed and utilized to mitigate catastrophic engine failures- a first in rocket engine health assessment. This paper is presented in viewgraph form.

Fiorucci, Tony R.↗

NASA NTRS2000

High Head Unshrouded Impeller Pump Stage Technology

A team of engineers at NASA/MSFC and Boeing, Rocketdyne division, are developing unshrouded impeller technologies that will increase payload and decrease cost of future reusable launch vehicles. Using the latest analytical techniques and experimental data, a two-stage unshrouded fuel pump is being designed that will meet the performance requirements of a three-stage shrouded pump. Benefits of the new pump include lower manufacturing costs, reduced weight, and increased payload to orbit.

Williams, Robert W.↗

NASA NTRS2000

MC-1 Nozzle Testing Results

This document is the presentation graphics which reviews the test results of the MC-1 Nozzle. The MC-1 Nozzle was originally designed for a low cost engine for an expendable booster. It was modified for use in the X-34 propulsion plant. With this design the nozzle and chamber are one piece. The presentation reviews the design goals, the materials and fabrication. The tests and results are reviewed in considerable detail. Included are pictures of the nozzle, and diagrams of the nozzle geometry

Peters, Warren↗

NASA NTRS2000

Observations on Rotating Cavitation and Cavitation Surge From The Development of the Fastrac Engine Turbopump

The effects of rotating cavitation and cavitation surges on the Fastrac Engine Turbopump are described in a viewgraph presentation format. The bent inducer blade dilemma and observations of unsteady data and oscillation components are discussed. The pump-feed system stability modeling assessment is outlined. Recommendations are made urging further investigation.

Zoladz, Thomas F.↗

NASA NTRS2000

High Head Unshrouded Impeller Pump Stage Technology

Objective to develop an unshrouded impeller design, which a meets the performance requirements of a 3-stage fuel pump with a 2-stage pump design, has been accomplished. Performance of the baseline unshrouded impeller has been experimentally verified. Unshrouded impeller trade study and final 6+6 unshrouded impeller configuration has been presented. Structurally viable, 6+6-impeller design concept has been produced. Based on results presented in this study, at a nominal 10% tip-clearance, the 6+6 impeller design would increase payload to orbit by almost 625 lbs. per engine. The RLV vehicle requires 7 engines, therefore, application of high head unshrouded technology would increase payload capability by as much as 4,375 lbs. per vehicle.

Williams, Robert W.↗

NASA NTRS2000

PDE Nozzle Optimization Using a Genetic Algorithm

Genetic algorithms, which simulate evolution in natural systems, have been used to find solutions to optimization problems that seem intractable to standard approaches. In this study, the feasibility of using a GA to find an optimum, fixed profile nozzle for a pulse detonation engine (PDE) is demonstrated. The objective was to maximize impulse during the detonation wave passage and blow-down phases of operation. Impulse of each profile variant was obtained by using the CFD code Mozart/2.0 to simulate the transient flow. After 7 generations, the method has identified a nozzle profile that certainly is a candidate for optimum solution. The constraints on the generality of this possible solution remain to be clarified.

Billings, Dana↗

NASA NTRS2000

Experiment/Analytical Characterization of the RBCC Rocket-Ejector Mode

Experimental and complementary CFD results from the study of the rocket-ejector mode of a Rocket Based Combined Cycle (RBCC) engine are presented and discussed. The experiments involved systematic flowfield measurements in a two-dimensional, variable geometry rocket-ejector system. The rocket-ejector system utilizes a single two-dimensional, gaseous oxygen/gaseous hydrogen rocket as the ejector. To gain a thorough understanding of the rocket-ejector's internal fluid mechanic/combustion phenomena, experiments were conducted with both direct-connect and sea-level static configurations for a range of rocket operating conditions. Overall system performance was obtained through global measurements of wall static pressure profiles, heat flux profiles and engine thrust, whereas detailed mixing and combustion information was obtained through Raman spectroscopy measurements of major species (oxygen, hydrogen, nitrogen and water vapor). The experimental results for both the direct-connect and sea-level static configurations are compared with CFD predictions of the flowfield.

Ruf, J. H.↗

NASA NTRS2000

FDNS CFD Code Benchmark for RBCC Ejector Mode Operation: Continuing Toward Dual Rocket Effects

Computational Fluid Dynamics (CFD) analysis results are compared with benchmark quality test data from the Propulsion Engineering Research Center's (PERC) Rocket Based Combined Cycle (RBCC) experiments to verify fluid dynamic code and application procedures. RBCC engine flowpath development will rely on CFD applications to capture the multi -dimensional fluid dynamic interactions and to quantify their effect on the RBCC system performance. Therefore, the accuracy of these CFD codes must be determined through detailed comparisons with test data. The PERC experiments build upon the well-known 1968 rocket-ejector experiments of Odegaard and Stroup by employing advanced optical and laser based diagnostics to evaluate mixing and secondary combustion. The Finite Difference Navier Stokes (FDNS) code [2] was used to model the fluid dynamics of the PERC RBCC ejector mode configuration. Analyses were performed for the Diffusion and Afterburning (DAB) test conditions at the 200-psia thruster operation point, Results with and without downstream fuel injection are presented.

West, Jeff↗

NASA NTRS2000

Evaluation of Vortex Chamber Concepts for Liquid Rocket Engine Applications

Rocket-based combined-cycle engines (RBBC) being considered at NASA for future generation launch vehicles feature clusters of small rocket thrusters as part of the engine components. Depending on specific RBBC concepts, these thrusters may be operated at various operating conditions including power level and/or propellant mixture ratio variations. To pursue technology developments for future launch vehicles, NASA/Marshall Space Flight Center (MSFC) is examining vortex chamber concepts for the subject cycle engine application. Past studies indicated that the vortex chamber schemes potentially have a number of advantages over conventional chamber methods. Due to the nature of the vortex flow, relatively cooler propellant streams tend to flow along the chamber wall. Hence, the thruster chamber can be operated without the need of any cooling techniques. This vortex flow also creates strong turbulence, which promotes the propellant mixing process. Consequently, the subject chamber concepts not only offer the system simplicity but they also would enhance the combustion performance. The test results showed that the chamber performance was markedly high even at a low chamber length-to- diameter ratio (L/D). This incentive can be translated to a convenience in the thrust chamber packaging.

Trinh, Huu Phuoc↗

NASA NTRS2000

Global Design Optimization for Aerodynamics and Rocket Propulsion Components

Modern computational and experimental tools for aerodynamics and propulsion applications have matured to a stage where they can provide substantial insight into engineering processes involving fluid flows, and can be fruitfully utilized to help improve the design of practical devices. In particular, rapid and continuous development in aerospace engineering demands that new design concepts be regularly proposed to meet goals for increased performance, robustness and safety while concurrently decreasing cost. To date, the majority of the effort in design optimization of fluid dynamics has relied on gradient-based search algorithms. Global optimization methods can utilize the information collected from various sources and by different tools. These methods offer multi-criterion optimization, handle the existence of multiple design points and trade-offs via insight into the entire design space, can easily perform tasks in parallel, and are often effective in filtering the noise intrinsic to numerical and experimental data. However, a successful application of the global optimization method needs to address issues related to data requirements with an increase in the number of design variables, and methods for predicting the model performance. In this article, we review recent progress made in establishing suitable global optimization techniques employing neural network and polynomial-based response surface methodologies. Issues addressed include techniques for construction of the response surface, design of experiment techniques for supplying information in an economical manner, optimization procedures and multi-level techniques, and assessment of relative performance between polynomials and neural networks. Examples drawn from wing aerodynamics, turbulent diffuser flows, gas-gas injectors, and supersonic turbines are employed to help demonstrate the issues involved in an engineering design context. Both the usefulness of the existing knowledge to aid current design practices and the need for future research are identified.

Shyy, Wei↗

NASA NTRS1998

The Advanced Reusable Technologies Project

Currently, NASA and its industry partners are performing ground testing of hydrogen-fueled rocket based combined-cycle flowpaths. Successful ramjet and scramjet testing at Mach 6 and scramjet testing at Mach 8 have been performed. Cold flow mixing tests have also been successfully performed as have inlet operability tests. Additional testing of RBCC flowpaths at air augmented rocket and rocket only modes is underway.

Turner, James E.↗