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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Corrosion Prevention in Copper Combustion Chamber Liners of Liquid Oxygen/Methane Booster Engines

Prior research conducted by United Technologies Research Center and Rockwell International Rocketdyne Division encountered severe copper corrosion while flowing hydrocarbon fuels through copper cooling tubes. These experimental results have very important implications for the development of low-cost, regeneratively cooled, oxygen/hydrocarbon bipropellant booster engines. Aerojet TechSystems undertook a program sponsored by NASA/Lewis Research Center in 1986 with two objectives: (1) to define the corrosive interaction process that occurs between hydrocarbon fuels and copper combustion chamber liner materials, using both static and dynamic test methods, and (2) to identify and demonstrate protective measures against this corrosive process. The results of the first program task demonstrated that the most damaging corrosive process was caused by trace amounts of sulfur-containing impurities in the hydrocarbon fuel which react with the copper chamber liner material to form cuprous sulfide (Cu2S), as reported in Paper No. AlAA 88-3215. Experiments were conducted which demonstrated this corrosive process with Mil-Spec RP-1, propane, and methane fuels in contact with OFHC, NASA-Z, and ZrCu coppers. The preliminary results of the second program task demonstrated that electrodeposited gold and platinum coatings held promise of preventing corrosion of copper chamber liners by methane contaminated with sulfur-containing impurities, as reported in Paper No. AIAA 89-2738. Experiments were conducted which demonstrated greatly reduced corrosion of copper by hydrogen sulfide (H2S) and methyl mercaptan (CH3SH) as measured impurities in methane. This paper presents the concluding, confirmatory results from the second program task. The efficacy of a protective gold coating on NASA-Z copper cooling channel walls was conclusively demonstrated. Tests were conducted in the Aerojet Carbothermal Test Facility which provide realistic simulations of booster engine cooling channel conditions such as temperature, pressure, flow velocity, and heat flux. Dynamic test series were performed with methane containing 5 and 10 ppm (by volume) hydrogen sulfide. Gold-plated and unplated copper alloy specimens were evaluated. The tests demonstrated that gold coatings were effective in preventing corrosion of the copper. Posttest metallographic examinations of the unplated specimens showed severe corrosion as a result of reaction with the sulfur containing contaminant in the fuel. In contrast, posttest metallographic examination of the gold-coated specimens showed no corrosion under similar operating conditions. The findings from metallurgical and chemical analyses of the copper specimens, chemical analysis of the methane, and description of all test conditions are provided. Conclusions are reached as to the efficacy of the plating methods and the effectiveness of the metal coatings in the prevention of corrosion in hydrocarbon-fueled booster engine combustion chamber liners.

S D Rosenberg↗
NASA NTRS1990

Summary of JAYGO mixing and FSM-1 application of castable inhibitor and liner

Two JAYGO planetary mixers (12 and 42 gallon) are being qualified to mix STW5-3224 liner and STW5-3223 castable inhibitor. These mixers are an integral part of a mix process which allows for safe addition of the asbestos component. An essential part of the engineering evaluation (ETP-0347) of these mixers is the generation of static test fire data. Ultimately, these results will help confirm the adequacy of these mixers for production mixing of liner and inhibitor. (These data are not required for qualification of the Certification Test Plan CTP-0125). The details on the mixing, inhibiting, and sling-lining of JAYGO-mixed castable inhibitor and liner which were applied to the FSM-1 segments are presented. The objectives are the following: (1) to document processing events surrounding the JAYO mixing of castable inhibitor and liner, and the subsequent inhibiting and sling lining onto the FSM-1 segments; and (2) to substantiate the measured properties of these JAYGO-mixed materials (rheological and mechanical) and compare these properties to existing production database.

Evans, Kurt B.↗
NASA NTRS1993

Subscale hot-fire testing of a formed platelet liner

To investigate low-cost options for fabricating main combustion chambers, formed platelet liners are being developed. The savings in manufacturing time and cost associated with platelet liners are accompanied by promising thermal advantages, such as lower-wall temperatures and increased cycle life. A subscale liner was tested by NASA at Marshall Space Flight Center (MSFC) to demonstrate its thermal performance. Testing to date has provided chamber pressures up to 2524 psia, while a maximum chamber pressure of 2700 psia is planned. In general, the liner has remained in good condition and performed well, with only minor areas of localized roughening. Data from this subscale test program is being used to develop a full size chamber for testing on a Space Shuttle Main Engine at MSFC in 1994.

Elam, Sandra K.↗
NASA NTRS1993

The photoionization mechanism of LINERs - Stellar and nonstellar

We present high quality spectroscopic observations of a sample of 14 LINERs. Starlight removal is achieved by the subtraction of a suitable absorption-line 'template' galaxy, allowing accurate measurements of emission lines. We use these line fluxes to examine the possible excitation mechanisms of LINERs. We suggest that LINERs with weak forbidden O I 6300-A emission may be H II regions photoionized by unusually hot O-type stars. LINERs with forbidden O I/H-alpha approximately greater than 1/6 may be powered by photoionization from a nonstellar continuum. This is supported by the detection of broad H-alpha emission, a correlation between line width and critical density, and pointlike X-ray emission in several of these objects.

Ho, Luis C.↗
NASA NTRS1999

Durability, Performance, and Emission of Diesel Engines Using Carbon Fiber Piston and Liner

This report summarizes the research conducted by NC State University in investigating the durability, performance and emission of a carbon fiber piston and liner in our single cylinder research Diesel engine. Both the piston and liner were supplied to NC State University by NASA LaRC and manufactured by C-CAT under a separate contract to NASA LaRC. The carbon-carbon material used to manufacture the piston and liner has significantly lower thermal conductivity, coefficient of thermal expansion, and superior strength characteristics at elevated temperatures when compared to conventional piston materials such as aluminum. The results of the carbon-carbon fiber piston testing were compared to a baseline configuration, which used a conventional aluminum piston in a steel liner. The parameters measured were the brake specific fuel consumption, ignition delay, frictional horsepower, volumetric efficiency, and durability characteristics of the two pistons. Testing was performed using a naturally aspirated Labeco Direct Injection single cylinder diesel engine. Two test cases were performed over a range of loads and speeds. The fixed test condition between the aluminum and carbon-carbon piston configurations was the brake mean effective pressure. The measured data was the fuel consumption rate, volumetric efficiency, load, speed, cylinder pressure, needle lift, and exhaust gas temperature. The cylinder pressure, and fuel consumption, exhaust gas temperature, and needle lift were recorded using a National Instruments DAQ board and a PC. All test cases used Diesel no. 2 for fuel.

Afify, E. M.↗
NASA NTRS2000

Experimental Impedance of Single Liner Elements with Bias Flow

An experimental investigation was conducted to generate a high quality database, from which the effects of a mean bias flow on the acoustic impedance of lumped-element single-degree-of-freedom liners was determined. Acoustic impedance measurements were made using the standard two-microphone method in the NASA Langley Normal Incidence Tube. Each liner consisted of a perforated sheet with a constant-area cavity. Liner resistance was shown to increase and to become less frequency and sound pressure level dependent as the bias flow was increased. The resistance was also consistently lower for a negative bias flow (suction) than for a positive bias flow (blowing) of equal magnitude. The slope of the liner reactance decreased with increased flow.

Follet, J. I.↗
NASA NTRS2001

MTF Driven by Plasma Liner Dynamically Formed by the Merging of Plasma Jets: An Overview

One approach for standoff delivery of the momentum flux for compressing the target in MTF consists of using a spherical array of plasma jets to form a spherical plasma shell imploding towards the center of a magnetized plasma, a compact toroid (Figure 1). A 3-year experiment (PLX-1) to explore the physics of forming a 2-D plasma liner (shell) by merging plasma jets is described. An overview showing how this 3-year project (PLX-1) fits into the program plan at the national and international level for realizing MTF for energy and propulsion is discussed. Assuming that there will be a parallel program in demonstrating and establishing the underlying physics principles of MTF using whatever liner is appropriate (e.g. a solid liner) with a goal of demonstrating breakeven by 2010, the current research effort at NASA MSFC attempts to complement such a program by addressing the issues of practical embodiment of MTF for propulsion. Successful conclusion of PLX-1 will be followed by a Physics Feasibility Experiment (PLX-2) for the Plasma Liner Driven MTF.

Thio, Y. C. Francis↗
NASA NTRS2002

Plasma Liner Research for MTF at NASA Marshall Space Flight Center

The current research effort at NASA Marshall Space Flight Center (MSFC) in MTF is directed towards exploring the critical physics issues of potential embodiments of MTF for propulsion, especially standoff drivers involving plasma liners for MTF. There are several possible approaches for forming plasma liners. One approach consists of using a spherical array of plasma jets to form a spherical plasma shell imploding towards the center of a magnetized plasma, a compact toroid. Current experimental plan and status to explore the physics of forming a 2-D plasma liner (shell) by merging plasma jets are described. A first-generation coaxial plasma guns (Mark-1) to launch the required plasma jets have been built and tested. Plasma jets have been launched reproducibly with a low jitter, and velocities in excess of 50 km/s for the leading edge of the plasma jet. Some further refinements are being explored for the plasma gun, Successful completion of these single-gun tests will be followed by an experimental exploration of the problems of launching a multiple number of these jets simultaneously to form a cylindrical plasma liner.

Thio, Y. C. F.↗
NASA NTRS2004

Analysis of Factors Affecting the Performance of RLV Thrust Cell Liners

The reusable launch vehicle (RLV) thrust cell liner, or thrust chamber, is a critical component of the Space Shuttle Main Engine (SSME). It is designed to operate in some of the most severe conditions seen in engineering practice. This requirement, in conjunction with experimentally observed 'dog-house' failure modes characterized by bulging and thinning of the cooling channel wall, provides the motivation to study the factors that influence RLV thrust cell liner performance. Factors or parameters believed to be directly related to the observed characteristic deformation modes leading to failure under in-service loading conditions are identified, and subsequently investigated using the cylindrical version of the higher-order theory for functionally graded materials in conjunction with the Robinson's unified viscoplasticity theory and the power-law creep model for modeling the response of the liner s constituents. Configurations are analyzed in which specific modifications in cooling channel wall thickness or constituent materials are made to determine the influence of these parameters on the deformations resulting in the observed failure modes in the outer walls of the cooling channel. The application of thermal barrier coatings and functional grading are also investigated within this context. Comparison of the higher-order theory results based on the Robinson and power-law creep model predictions has demonstrated that, using the available material parameters, the power-law creep model predicts more precisely the experimentally observed deformation leading to the 'dog-house' failure mode for multiple short cycles, while also providing much improved computational efficiency. However, for a single long cycle, both models predict virtually identical deformations. Increasing the power-law creep model coefficients produces appreciable deformations after just one long cycle that would normally be obtained after multiple cycles, thereby enhancing the efficiency of the analysis. This provides a basis for the development of an accelerated modeling procedure to further characterize dog-house deformation modes in RLV thrust cell liners. Additionally, the results presented herein have demonstrated that the mechanism responsible for deformation leading to 'dog-house' failure modes is driven by pressure, creep/relaxation and geometric effects.

Arnold, Steven M.↗
NASA NTRS2004

Friction Stir Welding of GR-Cop 84 for Combustion Chamber Liners

GRCop-84 is a copper-chromium-niobium alloy developed by the Glenn Research Center for liquid rocket engine combustion chamber liners. GRCop-84 exhibits superior properties over conventional copper-base alloys in a liquid hydrogen-oxygen operating environment. The Next Generation Launch Technology program has funded a program to demonstrate scale-up production capabilities of GR-Cop 84 to levels suitable for main combustion chamber production for the prototype rocket engine. This paper describes a novel method of manufacturing the main combustion chamber liner. The process consists of several steps: extrude the GR-Cop 84 powder into billets, roll the billets into plates, bump form the plates into cylinder halves and friction stir weld the halves into a cylinder. The cylinder is then metal spun formed to near net liner dimensions followed by finish machining to the final configuration. This paper describes the friction stir weld process development including tooling and non-destructive inspection techniques, culminating in the successful production of a liner preform completed through spin forming.

Russell, Carolyn K.↗
NASA NTRS2005

Large Engine Technology Program. Task 21: Rich Burn Liner for Near Term Experimental Evaluations

The objective of the task reported herein, which was conducted as part of the NASA sponsored Large Engine Technology program, was to define and evaluate a near-term rich-zone liner construction based on currently available materials and fabrication processes for a Rich-Quench-Lean combustor. This liner must be capable of operation at the temperatures and pressures of simulated HSCT flight conditions but only needs sufficient durability for limited duration testing in combustor rigs and demonstrator engines in the near future. This must be achieved at realistic cooling airflow rates since the approach must not compromise the emissions, performance, and operability of the test combustors, relative to the product engine goals. The effort was initiated with an analytical screening of three different liner construction concepts. These included a full cylinder metallic liner and one with multiple segments of monolithic ceramic, both of which incorporated convective cooling on the external surface using combustor airflow that bypassed the rich zone. The third approach was a metallic platelet construction with internal convective cooling. These three metal liner/jacket combinations were tested in a modified version of an existing Rich-Quench-Lean combustor rig to obtain data for heat transfer model refinement and durability verification.

Hautman, D. J.↗
NASA NTRS2005

Cracks in Flow Liners and Their Resolution

Cracks were detected in flow liners at the gimbal joints in the LH2 feedlines of the space shuttle's main engines. The cracks initiated at defects in the drainage slots of the flow liners and grew due to high cycle fatigue. Fracture mechanics analyses were conducted to evaluate the life of the liners. These analyses yielded extremely short lives in the presence of small surface or corner cracks. A high fidelity detection method, edge replication, was used to detect the very small cracks. The detected cracks were removed by polishing and the surface quality of the slots was reestablished to improve life of the liners.

Harris, C. E.↗
NASA NTRS2006

Fracture Mechanics Analysis of LH2 Feed Line Flow Liners

Inspections of the Space Shuttle Main Engine revealed fatigue cracks growing from slots in the flow liner of the liquid hydrogen (LH2) feed lines. During flight, the flow liners experience complex loading induced by flow of LH2 and the resonance characteristics of the structure. The flow liners are made of Inconel 718 and had previously not been considered a fracture critical component. However, fatigue failure of a flow liner could have catastrophic effect on the Shuttle engines. A fracture mechanics study was performed to determine if a damage tolerance approach to life management was possible and to determine the sensitivity to the load spectra, material properties, and crack size. The load spectra were derived separately from ground tests and material properties were obtained from coupon tests. The stress-intensity factors for the fatigue cracks were determined from a shell-dynamics approach that simulated the dominant resonant frequencies. Life predictions were obtained using the NASGRO life prediction code. The results indicated that adequate life could not be demonstrated for initial crack lengths of the size that could be detected by traditional NDE techniques.

James, Mark A.↗
NASA NTRS2006

Development of a Liner Design Methodology and Relevant Results of Acoustic Suppression in the Farfield for Mixer-Ejector Nozzles

We have developed a process to predict noise field interior to the ejector and in the farfield for any liner design for a mixer-ejector of arbitrary scale factor. However, a number of assumptions, not verified for the current application, utilized in this process, introduce uncertainties in the final result, especially, on a quantitative basis. The normal impedance model for bulk with perforated facesheet is based on homogeneous foam materials of low resistivity. The impact of flow conditions for HSCT application as well as the impact of perforated facesheet on predicted impedance is not properly accounted. Based on the measured normal impedance for deeper bulk samples (i.e., 2.0 in.) the predicted reactance is much higher compared to the data at frequencies above 2 kHz for T-foam and 200 ppi SiC. The resistance is under predicted at lower frequencies (below 4 kHz) for these samples. Thus, the use of such predicted data in acoustic suppression is likely to introduce inaccuracies. It should be noted that the impedance prediction methods developed recently under liner technology program are not utilized in the studies described in this report due to the program closeout. Acoustic suppression prediction is based on the uniform flow and temperature conditions in a two-sided treated constant area rectangular duct. In addition, assumptions of equal energy per mode noise field and interaction of all frequencies with the treated surface for the entire ejector length may not be accurate. While, the use of acoustic transfer factor minimizes the inaccuracies associated with the prediction for a known test case, the assumption of the same factor for other liner designs and with different linear scale factor ejectors seems to be very optimistic. As illustrated in appendix D that the predicted noise suppression for LSM-1 is lower compared to the measured data is an indication of the above argument. However, the process seems to be more reliable when used for the same scale models for different liner designs as demonstrated for Gen. 1 mixer-ejectors.

Salikuddin, M.↗
NASA NTRS2006

Development of Experimental and Computational Aeroacoustic Tools for Advanced Liner Evaluation

Acoustic liners in aircraft engine nacelles suppress radiated noise. Therefore, as air travel increases, increasingly sophisticated tools are needed to maximize noise suppression. During the last 30 years, NASA has invested significant effort in development of experimental and computational acoustic liner evaluation tools. The Curved Duct Test Rig is a 152-mm by 381- mm curved duct that supports liner evaluation at Mach numbers up to 0.3 and source SPLs up to 140 dB, in the presence of user-selected modes. The Grazing Flow Impedance Tube is a 51- mm by 63-mm duct currently being fabricated to operate at Mach numbers up to 0.6 with source SPLs up to at least 140 dB, and will replace the existing 51-mm by 51-mm duct. Together, these test rigs allow evaluation of advanced acoustic liners over a range of conditions representative of those observed in aircraft engine nacelles. Data acquired with these test ducts are processed using three aeroacoustic propagation codes. Two are based on finite element solutions to convected Helmholtz and linearized Euler equations. The third is based on a parabolic approximation to the convected Helmholtz equation. The current status of these computational tools and their associated usage with the Langley test rigs is provided.

Jones, Michael G.↗
NASA NTRS1994

Liner mounting assembly

A mounting assembly includes an annular supporting flange disposed coaxially about a centerline axis which has a plurality of circumferentially spaced apart supporting holes therethrough. An annular liner is disposed coaxially with the supporting flange and includes a plurality of circumferentially spaced apart mounting holes aligned with respective ones of the supporting holes. Each of a plurality of mounting pins includes a proximal end fixedly joined to the supporting flange through a respective one of the supporting holes, and a distal end disposed through a respective one of the liner mounting holes for supporting the liner to the supporting flange while unrestrained differential thermal movement of the liner relative to the supporting flange.

Halila, Ely E.↗
NASA NTRS1995

Turbulator for a liner cooling jacket

A turbulator for a liner cooling jacket includes a metal panel which is suitable to be coiled into a generally cylindrical shape so as to be placed in a relief area between an engine cylinder block and a cylinder liner. The relief area may be machined into either the block or the cylinder liner and the metal panel is formed with a pattern of protuberances shaped like corrugations. In one embodiment, the corrugations have a shape similar to a sine wave and are arranged in a plurality of generally parallel axial segments. The corrugation wave pattern of one segment may be the same as its adjacent segment or may be staggered by one corrugation which would mean one-half of a full wave cycle. The corrugation pattern in the turbulator panel may be created by any one of various stamping or forming operations and when placed between the cylinder liner and block, increases turbulence of the cooling liquid in order to enhance heat transfer.

Hoag, Kevin L.↗
NASA NTRS2008

Assessment of 3D Codes for Predicting Liner Attenuation in Flow Ducts

This paper presents comparisons of seven propagation codes for predicting liner attenuation in ducts with flow. The selected codes span the spectrum of methods available (finite element, parabolic approximation, and pseudo-time domain) and are collectively representative of the state-of-art in the liner industry. These codes are included because they have two-dimensional and three-dimensional versions and can be exported to NASA's Columbia Supercomputer. The basic assumptions, governing differential equations, boundary conditions, and numerical methods underlying each code are briefly reviewed and an assessment is performed based on two predefined metrics. The two metrics used in the assessment are the accuracy of the predicted attenuation and the amount of wall clock time to predict the attenuation. The assessment is performed over a range of frequencies, mean flow rates, and grazing flow liner impedances commonly used in the liner industry. The primary conclusions of the study are (1) predicted attenuations are in good agreement for rigid wall ducts, (2) the majority of codes compare well to each other and to approximate results from mode theory for soft wall ducts, (3) most codes compare well to measured data on a statistical basis, (4) only the finite element codes with cubic Hermite polynomials capture extremely large attenuations, and (5) wall clock time increases by an order of magnitude or more are observed for a three-dimensional code relative to the corresponding two-dimensional version of the same code.

Watson, W. R.↗