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NASA NTRS2003

Data-Mining Toolset Developed for Determining Turbine Engine Part Life Consumption

The current practice in aerospace turbine engine maintenance is to remove components defined as life-limited parts after a fixed time, on the basis of a predetermined number of flight cycles. Under this schedule-based maintenance practice, the worst-case usage scenario is used to determine the usable life of the component. As shown, this practice often requires removing a part before its useful life is fully consumed, thus leading to higher maintenance cost. To address this issue, the NASA Glenn Research Center, in a collaborative effort with Pratt & Whitney, has developed a generic modular toolset that uses data-mining technology to parameterize life usage models for maintenance purposes. The toolset enables a "condition-based" maintenance approach, where parts are removed on the basis of the cumulative history of the severity of operation they have experienced. The toolset uses data-mining technology to tune life-consumption models on the basis of operating and maintenance histories. The flight operating conditions, represented by measured variables within the engine, are correlated with repair records for the engines, generating a relationship between the operating condition of the part and its service life. As shown, with the condition-based maintenance approach, the lifelimited part is in service until its usable life is fully consumed. This approach will lower maintenance costs while maintaining the safety of the propulsion system. The toolset is a modular program that is easily customizable by users. First, appropriate parametric damage accumulation models, which will be functions of engine variables, must be defined. The tool then optimizes the models to match the historical data by computing an effective-cycle metric that reduces the unexplained variability in component life due to each damage mode by accounting for the variability in operational severity. The damage increment due to operating conditions experienced during each flight is used to compute the effective cycles and ultimately the replacement time. Utilities to handle data problems, such as gaps in the flight data records, are included in the toolset. The tool was demonstrated using the first stage, high-pressure turbine blade of the PW4077 engine (Pratt & Whitney, East Hartford, CT). The damage modes considered were thermomechanical fatigue and oxidation/erosion. Each PW4077 engine contains 82 first-stage, high-pressure turbine blades, and data from a fleet of engines were used to tune the life-consumption models. The models took into account not only measured variables within the engine, but also unmeasured variables such as engine health parameters that are affected by degradation of the engine due to aging. The tool proved effective at predicting the average number of blades scrapped over time due to each damage mode, per engine, given the operating history of the engine. The customizable tools are available to interested parties within the aerospace community.

Litt, Jonathan S.↗

NASA NTRS1952

Altitude Investigation of Gas Temperature Distribution at Turbine of Three Similar Axial-Flow Turbojet Engines

An investigation of the effect of inlet pressure, corrected engine speed, and turbine temperature level on turbine-inlet gas temperature distributions was conducted on a J40-WE-6, interim J40-WE-6, and prototype J40-WE-8 turbojet engine in the altitude wind tunnel at the NAC.4 Lewis laboratory. The engines were investigated over a range of simulated pressure altitudes from 15,000 to 55,000 feet, flight Mach numbers from 0.12 to 0.64, and corrected engine speeds from 7198 to 8026 rpm, The gas temperature distribution at the turbine of the three engines over the range of operating conditions investigated was considered satisfactory from the standpoint of desired temperature distribution with one exception - the distribution for the J40-WE-6 engine indicated a trend with decreasing engine-inlet pressure for the temperature to exceed the desired in the region of the blade hub. Installation of a compressor-outlet mixer vane assembly remedied this undesirable temperature distribution, The experimental data have shown that turbine-inlet temperature distributions are influenced in the expected manner by changes in compressor-outlet pressure or mass-flow distribution and by changes in combustor hole-area distribution. The similarity between turbine-inlet and turbine-outlet temperature distribution indicated only a small shift in temperature distribution imposed by the turbine rotors. The attainable jet thrusts of the three engines were influenced in different degrees and directions by changes in temperature distributions with change in engine-inlet pressure. Inability to match the desired temperature distribution resulted, for the J40-WE-6 engine, in an 11-percent thrust loss based on an average turbine-inlet temperature of 1500 F at an engine-inlet pressure of 500 pounds per square foot absolute. Departure from the desired temperature distribution in the Slade tip region results, for the prototype J40-WE-8 engine, in an attainable thrust increase of 3 to 4 percent as compared with that obtained if tip-region temperature limitations were observed.

Prince, W.R.↗

NASA NTRS2010

Planning for Plume Diagnostics for Ground Testing of J-2X Engines at the SSC

John C. Stennis Space Center (SSC) is the premier test facility for liquid rocket engine development and certification for the National Aeronautics and Space Administration (NASA). Therefore, it is no surprise that the SSC will play the most prominent role in the engine development testing and certification for the J-2X engine. The Pratt & Whitney Rocketdyne J-2X engine has been selected by the Constellation Program to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage in NASA s strategy of risk mitigation for hardware development by building on the Apollo program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. Accordingly, J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development and testing efforts. In order to leverage SSC s successful and innovative expertise in the plume diagnostics for the space shuttle main engine (SSME) health monitoring,1-10 this paper will present a blueprint for plume diagnostics for various proposed ground testing activities for J-2X at SSC. Complete description of the SSC s test facilities, supporting infrastructure, and test facilities is available in Ref. 11. The A-1 Test Stand is currently being prepared for testing the J-2X engine at sea level conditions. The A-2 Test Stand is currently being used for testing the SSME and may also be used for testing the J-2X engine at sea level conditions in the future. Very recently, ground-breaking ceremony for the new A-3 rocket engine test stand took place at SSC on August 23, 2007. A-3 is the first large - scale test stand to be built at the SSC since the A and B stands were constructed in the 1960s. The A-3 Test Stand will be used for testing J-2X engines under vacuum conditions simulating high altitude operation at approximately 30,480 m (100,000 ft). To achieve the simulated altitude environment, chemical steam generators using isopropyl alcohol, LOX, and RELEASED - Printed documents may be obsolete; validate prior to use. water would run for the duration of the test and would generate approximately 2096 Kg/s of steam to reduce pressure in the test cell and downstream of the engine. The testing at the A-3 Test Stand is projected to begin in late 2010, meanwhile the J-2X component testing on A-1 is scheduled to begin later this year.

SaintCyr, William W.↗

NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

The research and development activities reported in this publication were carried out under NASA Aeronautics Research Institute (NARI) funded project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing." The objective of the project was to conduct evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. The results of the activities are described in three part report. The first part of the report contains the data and analysis of engine system trade studies, which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. The technical scope of activities included an assessment of the feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composites, which were accomplished by fabricating prototype engine components and testing them in simulated engine operating conditions. The manufacturing process parameters were developed and optimized for polymer and ceramic composites (described in detail in the second and third part of the report). A number of prototype components (inlet guide vane (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included turbine nozzle components. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

acoustic liners↗

NASA NTRS1999

A New Method to Measure Temperature and Burner Pattern Factor Sensing for Active Engine Control

The determination of the temperatures of extended surfaces which exhibit non-uniform temperature variation is very important for a number of applications including the "Burner Pattern Factor" (BPF) of turbine engines. Exploratory work has shown that use of BPF to control engine functions can result in many benefits, among them reduction in engine weight, reduction in operating cost, increase in engine life, while attaining maximum engine efficiency. Advanced engines are expected to operate at very high temperature to achieve high efficiency. Brief exposure of engine components to higher than design temperatures due to non-uniformity in engine burner pattern can reduce engine life. The engine BPF is a measure of engine temperature uniformity. Attainment of maximum temperature uniformity and high temperatures is key to maximum efficiency and long life. A new approach to determine through the measurement of just one radiation spectrum by a multiwavelength pyrometer is possible. This paper discusses a new temperature sensing approach and its application to determine the BPF.

Ng, Daniel↗

NASA NTRS2001

X-traktor: A Rookie Robot, Simple, Yet Complex, Impeccably Designed, a Very Innovative Multidisciplinary Engineering Masterpiece

FIRST is the acronym of For Inspiration and Recognition of Science and Technology. FIRST is a 501.C.3 non-profit organization whose mission is to generate an interest in science and engineering among today's young adults and youth. This mission is accomplished through a robot competition held annually in the spring of each year. NASAs Marshall Space Flight Center, Education Programs Department, awarded a grant to Lee High School, the sole engineering magnet school in Huntsville, Alabama. MSFC awarded the grant in hopes of fulfilling its goal of giving back invaluable resources to its community and engineers, as well as educating tomorrow's work force in the high-tech area of science and technology. Marshall engineers, Lee High School students and teachers, and a host of other volunteers and parents officially initiated this robot design process and competitive strategic game plan. The FIRST Robotics Competition is a national engineering contest, which immerses high school students in the exciting world of science and engineering. Teaming with engineers from government agencies, businesses, and universities enables the students to learn about the engineering profession. The students and engineers have six weeks to work together to brainstorm, design, procure, construct, and test their robot. The team then competes in a spirited, 'no-holds barred' tournament, complete with referees, other FIRST-designed robots, cheerleaders, and time clocks. The partnerships developed between schools, government agencies, businesses, and universities provide an exchange of resources and talent that build cooperation and expose students to new and rewarding career options. The result is a fun, exciting, and stimulating environment in which all participants discover the important connections between classroom experiences and real-world applications. This paper will highlight the story, engineering development, and evolutionary design of Xtraktor, the rookie robot, a manufacturing marvel and engineering achievement.

Henderson, A. J., Jr.↗

NASA NTRS2003

RS-84 Engine

The RS-84 is the first reusable hydrocarbon staged combustion liquid rocket engine. This engine is being developed to meet NASA s crew safety goals with a highly reliable and low cost main engine as a part of the NASA Space Launch Initiative program for the next generation reusable launch system. The NASA-MSFC and Rocketdyne team brings over 50 years of successful rocket engine development experience to meet the challenges of this new program. This team s extensive design database has been anchored with almost five decades of hydrocarbon rocket engine development and flight operations experience including Delta, Atlas, and Saturn vehicles and nearly three decades of successfully operating the world s only reusable pump-fed rocket engine, the Space Shuttle Main Engine. The team also fully benefits from the proven and experienced engineering staffs that recently completed the successful MC-1 FASTRAC , XRS-2200, and RS-68 engine development programs and the ongoing IPD and RS-76 technology development. Advances in integrated parametric design and analysis tools, advanced materials knowledge base, and state-of-the-art fabrication processes anchored and refined during the recent engine development programs are already being used by the team to design this engine.

Stegman, E.↗

NASA NTRS1948

Altitude-Wind-Tunnel Investigation of a 4000-Pound-Thrust Axial-Flow Turbojet Engine. II - Operational Characteristics: Operational Characteristics - II

An investigation was conducted in the Cleveland altitude wind tunnel to determine the operational characteristics of an axial flow-type turbojet engine with a 4000-pound-thrust rating over a range of pressure altitudes from 5,000 to 50,OOO feet, ram pressure ratios from 1.00 to 1.86, and temperatures from 60 deg to -50 deg F. The low-flow (standard) compressor with which the engine was originally equipped was replaced by a high-flow compressor for part of the investigation. The effects of altitude and airspeed on such operating characteristics as operating range, stability of combustion, acceleration, starting, operation of fuel-control systems, and bearing cooling were investigated. With the low-flow compressor, the engine could be operated at full speed without serious burner unbalance at altitudes up to 50,000 feet. Increasing the altitude and airspeed greatly reduced the operable speed range of the engine by raising the minimum operating speed of the engine. In several runs with the high-flow compressor the maximum engine speed was limited to less than 7600 rpm by combustion blow-out, high tail-pipe temperatures, and compressor stall. Acceleration of the engine was relatively slow and the time required for acceleration increased with altitude. At maximum engine speed a sudden reduction in jet-nozzle area resulted in an immediate increase in thrust. The engine started normally and easily below 20,000 feet with each configuration. The use of a high-voltage ignition system made possible starts at a pressure altitude of 40,000 feet; but on these starts the tail-pipe temperatures were very high, a great deal of fuel burned in and behind the tail-pipe, and acceleration was very slow. Operation of the engine was similar with both fuel regulators except that the modified fuel regulator restricted the fuel flow in such a manner that the acceleration above 6000 rpm was very slow. The bearings did not cool properly at high altitudes and high engine speeds with a low-flow compressor, and bearing cooling was even poorer with a high-flow compressor.

Fleming, William A.↗

NASA NTRS2000

Aerospike Engine Post-Test Diagnostic System Delivered to Rocketdyne

The NASA Glenn Research Center at Lewis Field, in cooperation with Rocketdyne, has designed, developed, and implemented an automated Post-Test Diagnostic System (PTDS) for the X-33 linear aerospike engine. The PTDS was developed to reduce analysis time and to increase the accuracy and repeatability of rocket engine ground test fire and flight data analysis. This diagnostic system provides a fast, consistent, first-pass data analysis, thereby aiding engineers who are responsible for detecting and diagnosing engine anomalies from sensor data. It uses analytical methods modeled after the analysis strategies used by engineers. Glenn delivered the first version of PTDS in September of 1998 to support testing of the engine s power pack assembly. The system was used to analyze all 17 power pack tests and assisted Rocketdyne engineers in troubleshooting both data acquisition and test article anomalies. The engine version of PTDS, which was delivered in June of 1999, will support all single-engine, dual-engine, and flight firings of the aerospike engine.

Meyer, Claudia M.↗

NASA NTRS2006

Selected Systems Engineering Process Deficiencies and Their Consequences

The systems engineering process is well established and well understood. While this statement could be argued in the light of the many systems engineering guidelines and that have been developed, comparative review of these respective descriptions reveal that they differ primarily in the number of discrete steps or other nuances, and are at their core essentially common. Likewise, the systems engineering textbooks differ primarily in the context for application of systems engineering or in the utilization of evolved tools and techniques, not in the basic method. Thus, failures in systems engineering cannot credibly be attributed to implementation of the wrong systems engineering process among alternatives. However, numerous systems failures can be attributed to deficient implementation of the systems engineering process. What may clearly be perceived as a system engineering deficiency in retrospect can appear to be a well considered system engineering efficiency in real time - an efficiency taken to reduce cost or meet a schedule, or more often both. Typically these efficiencies are grounded on apparently solid rationale, such as reuse of heritage hardware or software. Over time, unintended consequences of a systems engineering process deficiency may begin to be realized, and unfortunately often the consequence is system failure. This paper describes several actual cases of system failures that resulted from deficiencies in their systems engineering process implementation, including the Ariane 5 and the Hubble Space Telescope.

Thomas, Lawrence Dale↗

NASA NTRS2016

Systems Engineering and Management Applications of ISO 9001:2015 for Government

The manufacturing segment of the business world is busy assessing the impact of ISO 9001:2015, and updating their management systems to meet the required compliance date. What does the new revision mean for government agencies that deliver large engineering projects rather than mass production? In fact, the standard, especially the new revision, can be used quite readily for government agencies, or applied to specific projects, once it is understood in terms of the similarities with systems engineering and project management. From there it can be extrapolated to "mission realization" systems, and a Quality Management System (QMS) is a logical result that can bring order to processes and systems that likely already exist in some fashion. ISO 9001:2015 is less product-oriented than previous versions. It can be more broadly applied to public organizations as well as private; and to services (missions) as well as products. The emphasis on risk management in the revised standard provides the needed balance for weighing decisions with respect to cost, schedule, technical, safety, and regulatory compliance; so if this is not part of agency governance already, this is a good place to start, especially for large engineering projects. The Systems Engineering standard used for this analysis is from NASA's NPR 7123.1 NASA Systems Engineering Processes and Requirements; however, those who are more familiar with ISO/IEC 26702 Systems Engineering-application and management of the systems engineering process, or SAE/EIA 632 Processes for Engineering a System will also recognize the similarities. In reality, the QMS outlined by ISO 9001 reinforces the systems engineering processes, and serves to ensure that they are adequately implemented, although most of the ISO 9001 literature emphasizes the production and process aspects of the standard. Rather than beginning with ISO 9001and getting lost in the vocabulary, it is useful to begin with the systems engineering lifecycle. Identification of stakeholder expectations, identifying solutions, creating specific product or service designs, production of the product or service, delivery to the public, and the associated management, planning, and control processes, are a familiar place to begin thinking of the overall system of identifying, designing, and competing a project or mission. Lining up this lifecycle with the ISO requirements (see Figure 1) illustrates how a quality management system is concerned with the same processes, and provides a governance and assurance function. If implemented properly, there are cost savings resulting from less rework, repair, reprocessing, failures, misplaced documents, and similar types of deficiencies1. Starting with an organization's systems engineering processes allows the organization to use their own terminology for a QMS plan, and tailor the plan to their own project or organization, so that it is more easily developed, understood, and implemented.

Shepherd, Christena C.↗

NASA NTRS2016

NASA Systems Engineering Research Consortium: Defining the Path to Elegance in Systems

The NASA Systems Engineering Research Consortium was formed at the end of 2010 to study the approaches to producing elegant systems on a consistent basis. This has been a transformative study looking at the engineering and organizational basis of systems engineering. The consortium has engaged in a variety of research topics to determine the path to elegant systems. In the second year of the consortium, a systems engineering framework emerged which structured the approach to systems engineering and guided our research. This led in the third year to set of systems engineering postulates that the consortium is continuing to refine. The consortium has conducted several research projects that have contributed significantly to the understanding of systems engineering. The consortium has surveyed the application of the NASA 17 systems engineering processes, explored the physics and statistics of systems integration, and considered organizational aspects of systems engineering discipline integration. The systems integration methods have included system exergy analysis, Akaike Information Criteria (AIC), State Variable Analysis, Multidisciplinary Coupling Analysis (MCA), Multidisciplinary Design Optimization (MDO), System Cost Modelling, System Robustness, and Value Modelling. Organizational studies have included the variability of processes in change evaluations, margin management within the organization, information theory of board structures, social categorization of unintended consequences, and initial looks at applying cognitive science to systems engineering. Consortium members have also studied the bidirectional influence of policy and law with systems engineering.

Watson, Michael D.↗

NASA NTRS2016

NASA Systems Engineering Research Consortium: Defining the Path to Elegance in Systems

The NASA Systems Engineering Research Consortium was formed at the end of 2010 to study the approaches to producing elegant systems on a consistent basis. This has been a transformative study looking at the engineering and organizational basis of systems engineering. The consortium has engaged in a variety of research topics to determine the path to elegant systems. In the second year of the consortium, a systems engineering framework emerged which structured the approach to systems engineering and guided our research. This led in the third year to set of systems engineering postulates that the consortium is continuing to refine. The consortium has conducted several research projects that have contributed significantly to the understanding of systems engineering. The consortium has surveyed the application of the NASA 17 systems engineering processes, explored the physics and statistics of systems integration, and considered organizational aspects of systems engineering discipline integration. The systems integration methods have included system energy analysis, Akaike Information Criteria (AIC), State Variable Analysis, Multidisciplinary Coupling Analysis (MCA), Multidisciplinary Design Optimization (MDO), System Cost Modeling, System Robustness, and Value Modeling. Organizational studies have included the variability of processes in change evaluations, margin management within the organization, information theory of board structures, social categorization of unintended consequences, and initial looks at applying cognitive science to systems engineering. Consortium members have also studied the bidirectional influence of policy and law with systems engineering.

Watson, Michael D.↗

NASA NTRS2015

Affordable Development and Demonstration of a Small NTR Engine and Stage: How Small is Big Enough?

The Nuclear Thermal Rocket (NTR) derives its energy from fission of uranium-235 atoms contained within fuel elements that comprise the engine's reactor core. It generates high thrust and has a specific impulse potential of approximately 900 seconds - a 100% increase over today's best chemical rockets. The Nuclear Thermal Propulsion (NTP) project, funded by NASA's AES program, includes five key task activities: (1) Recapture, demonstration, and validation of heritage graphite composite (GC) fuel (selected as the "Lead Fuel" option); (2) Engine Conceptual Design; (3) Operating Requirements Definition; (4) Identification of Affordable Options for Ground Testing; and (5) Formulation of an Affordable Development Strategy. During FY'14, a preliminary DDT&E plan and schedule for NTP development was outlined by GRC, DOE and industry that involved significant system-level demonstration projects that included GTD tests at the NNSS, followed by a FTD mission. To reduce cost for the GTD tests and FTD mission, small NTR engines, in either the 7.5 or 16.5 klbf thrust class, were considered. Both engine options used GC fuel and a "common" fuel element (FE) design. The small approximately 7.5 klbf "criticality-limited" engine produces approximately 157 megawatts of thermal power (MWt) and its core is configured with parallel rows of hexagonal-shaped FEs and tie tubes (TTs) with a FE to TT ratio of approximately 1:1. The larger approximately 16.5 klbf Small Nuclear Rocket Engine (SNRE), developed by LANL at the end of the Rover program, produces approximately 367 MWt and has a FE to TT ratio of approximately 2:1. Although both engines use a common 35 inch (approximately 89 cm) long FE, the SNRE's larger diameter core contains approximately 300 more FEs needed to produce an additional 210 MWt of power. To reduce the cost of the FTD mission, a simple "1-burn" lunar flyby mission was considered to reduce the LH2 propellant loading, the stage size and complexity. Use of existing and flight proven liquid rocket and stage hardware (e.g., from the RL10B-2 engine and Delta Cryogenic Second Stage) was also maximized to further aid affordability. This paper examines the pros and cons of using these two small engine options, including their potential to support future human exploration missions to the Moon, near Earth asteroids, and Mars, and recommends a preferred size. It also provides a preliminary assessment of the key activities, development options, and schedule required to affordably build, ground test and fly a small NTR engine and stage within a 10-year timeframe.

Spacecraft design↗

NASA NTRS2016

Affordable Development and Demonstration of a Small Nuclear Thermal Rocket (NTR) Engine and Stage: How Small Is Big Enough?

The Nuclear Thermal Rocket (NTR) derives its energy from fission of uranium-235 atoms contained within fuel elements that comprise the engine's reactor core. It generates high thrust and has a specific impulse potential of approximately 900 specific impulse - a 100 percent increase over today's best chemical rockets. The Nuclear Thermal Propulsion (NTP) project, funded by NASA's Advanced Exploration Systems (AES) program, includes five key task activities: (1) Recapture, demonstration, and validation of heritage graphite composite (GC) fuel (selected as the Lead Fuel option); (2) Engine Conceptual Design; (3) Operating Requirements Definition; (4) Identification of Affordable Options for Ground Testing; and (5) Formulation of an Affordable Development Strategy. During fiscal year (FY) 2014, a preliminary Design Development Test and Evaluation (DDT&E) plan and schedule for NTP development was outlined by the NASA Glenn Research Center (GRC), Department of Energy (DOE) and industry that involved significant system-level demonstration projects that included Ground Technology Demonstration (GTD) tests at the Nevada National Security Site (NNSS), followed by a Flight Technology Demonstration (FTD) mission. To reduce cost for the GTD tests and FTD mission, small NTR engines, in either the 7.5 or 16.5 kilopound-force thrust class, were considered. Both engine options used GC fuel and a common fuel element (FE) design. The small approximately 7.5 kilopound-force criticality-limited engine produces approximately157 thermal megawatts and its core is configured with parallel rows of hexagonal-shaped FEs and tie tubes (TTs) with a FE to TT ratio of approximately 1:1. The larger approximately 16.5 kilopound-force Small Nuclear Rocket Engine (SNRE), developed by Los Alamos National Laboratory (LANL) at the end of the Rover program, produces approximately 367 thermal megawatts and has a FE to TT ratio of approximately 2:1. Although both engines use a common 35-inch (approximately 89-centimeters) -long FE, the SNRE's larger diameter core contains approximately 300 more FEs needed to produce an additional 210 thermal megawatts of power. To reduce the cost of the FTD mission, a simple one-burn lunar flyby mission was considered to reduce the liquid hydrogen (LH2) propellant loading, the stage size and complexity. Use of existing and flight proven liquid rocket and stage hardware (e.g., from the RL10B-2 engine and Delta Cryogenic Second Stage) was also maximized to further aid affordability. This paper examines the pros and cons of using these two small engine options, including their potential to support future human exploration missions to the Moon, near Earth asteroids (NEA), and Mars, and recommends a preferred size. It also provides a preliminary assessment of the key activities, development options, and schedule required to affordably build, ground test and fly a small NTR engine and stage within a 10-year timeframe.

Spacecraft design↗

NASA NTRS2019

Scaling Evaluation of Ice-Crystal Icing on a Modern Turbofan Engine in PSL Using the COMDES-MELT Code

This paper presents preliminary ice-crystal icing (ICI) altitude scaling evaluation results of a Honeywell Uncertified Research Engine (HURE) that was tested in the NASA Glenn Research Center Propulsion Systems Laboratory (PSL) during January of 2018. This engine geometry features a hidden core design to keep the core less exposed. The engine was fitted with internal video cameras to observe various ice buildup processes at multiple selected locations within the engine core flow path covering the fan stator, the splitter-lip/shroud/strut, and the high pressure compressor (HPC) variable inlet guide vane (IGV) regions. The potential ice accretion risk was pre-determined to occur by using NASA’s in-house 1D Engine Icing Risk assessment code, COMDES-MELT. The code was successful in predicting the risk of ice accretion in adiabatic regions like the fan-stator of the HURE at specific engine operating points. However at several operating points during the test, liquid water was observed running along the shroud toward the variable IGV of the HPC regions with an air temperature well below freezing, thus no particle melting could have occurred due to heating from the air alone. It was reasoned that other sources of heat were present in that region. To account for these heat sources the inlet total temperature was adjusted to give a wet bulb temperature of 24 F below the standard minimum wet bulb temperature of 492 R to allow ice to accrete in the splitter-lip/shroud/strut region, which was determined from a reference case where hard ice was observed in that region. With that adjustment the COMDES-MELT code was successful in providing operating points where there was a risk of ice accretion during the test campaign. In addition to calculating possible conditions at different selected lower altitudes, simulations were run to determine potential inlet conditions that could lead to ice-crystal accretion along the prescribed stations where the cameras were available. From there, scaled test conditions were determined by best matching the following three icing related parameters of the reference condition: (1) the local air total wet bulb temperature, (2) the local ice crystal cloud melt ratio and (3) the engine fan face ice/water to air mass flux ratio of the ice crystal cloud. Instantaneous images taken from the time-lapsed movies of ice buildup were used along with the relevant thermodynamic data of air, water vapor and local icing condition to help evaluate how closely the proposed altitude scaling method could be used in ground based test facility to duplicate selected reference ICI features observed at specific location inside this engine at different scale altitudes. Discussions on observed limitation for engine icing scaling application from this test campaign and needed improvement are provided. A scaling test procedure to help identify potential ICI risk conditions and possible ice accretion locations of a new turbofan engine is evaluated in PSL.

Engine Testing in PSL↗

NASA NTRS1966

Commerical application of rocket engine turbopump technology

This paper describes how commercial pump technology was modified for rocket engine application by trading long life for low weight. The component life of typical turbopump components is presented, and the modes of failure will be discussed. A comparison of the basic commercial and rocket engine pump requirements such as flow, pressure, etc. is made. It is concluded that rocket engine pump technology can be applied directly only if similar basic requirements exist in emergency or stand-by equipment. The specific design requirements for rocket engine turbopumps are presented and the need for high speeds is explained by the weight-speed relationship and the optimum NPSH of the tank and pump system. The trend of required rocket engine pump discharge pressure and future operational requirements is predicted. The need for inducers and boost pumps in rocket engines is explained, and the results of the flat-plate-inducer cavitation therein are briefly presented. Design solutions and material selections for high-pressure pump housings, ultra-high tip speed impellers, and pump packaging are demonstrated. As a typical example of utilizing rocket engine technology for commercial application, a helicopter stand-by engine i shown. This standby engine is designed from existing rocket engine components, using JATO rockets as the prime energy source.

Turbopump↗

NASA NTRS1977

High frequency dynamic engine simulation

A digital computer simulation of a mixed flow, twin spool turbofan engine was assembled to evaluate and improve the dynamic characteristics of the engine simulation to disturbance frequencies of at least 100 Hz. One dimensional forms of the dynamic mass, momentum and energy equations were used to model the engine. A TF30 engine was simulated so that dynamic characteristics could be evaluated against results obtained from testing of the TF30 engine at the NASA Lewis Research Center. Dynamic characteristics of the engine simulation were improved by modifying the compression system model. Modifications to the compression system model were established by investigating the influence of size and number of finite dynamic elements. Based on the results of this program, high frequency engine simulations using finite dynamic elements can be assembled so that the engine dynamic configuration is optimum with respect to dynamic characteristics and computer execution time. Resizing of the compression systems finite elements improved the dynamic characteristics of the engine simulation but showed that additional refinements are required to obtain close agreement simulation and actual engine dynamic characteristics.

Schuerman, J. A.↗