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NASA NTRS1993

Fundamental rocket injector/spray programs at the Phillips Laboratory

The performance and stability of liquid rocket engines is determined to a large degree by atomization, mixing, and combustion processes. Control over these processes is exerted through the design of the injector. Injectors in liquid rocket engines are called upon to perform many functions. They must first of all mix the propellants to provide suitable performance in the shortest possible length. For main injectors, this is driven by the tradeoff between the combustion chamber performance, stability, efficiency, and its weight and cost. In gas generators and preburners, however, it is also driven by the possibility of damage to downstream components, for example piping and turbine blades. This can occur if unburned fuel and oxidant later react to create hot spots. Weight and cost considerations require that the injector design be simple and lightweight. For reusable engines, the injectors must also be durable and easily maintained. Suitable atomization and mixing must be produced with as small a pressure drop as possible, so that the size and weight of pressure vessels and turbomachinery can be minimized. However, the pressure drop must not be so small as to promote feed system coupled instabilities. Another important function of the injectors is to ensure that the injector face plate and the chamber and nozzle walls are not damaged. Typically this requires reducing the heat transfer to an acceptable level and also keeping unburned oxygen from chemically attacking the walls, particularly in reusable engines. Therefore the mixing distribution is often tailored to be fuel-rich near the walls. Wall heat transfer can become catastrophically damaging in the presence of acoustic instabilities, so the injector must prevent these from occurring at all costs. In addition to acoustic stability (but coupled with it), injectors must also be kinetically stable. That is, the flame itself must maintain ignition in the combustion chamber. This is not typically a problem with main injectors, but can be a consideration in preburners, where the desire to keep turbine inlet temperatures as cool as possible can make it advantageous for the preburners to operate as far from stoichiometry as can be tolerated. For some missions such as single stage to orbit, all of the above requirements must be maintained over a throttleable range, for example 5:1 to 10:1. Finally, the injectors must be ignitable during startup where pressures and temperatures are far from design conditions, and ignition transients must be minimized in order to avoid damage to engine components. In order to satisfy these various constraints, the injector designer must be able to perform design tradeoff studies, and it is important that this be done with minimal time and costs. In fact, it can easily be argued that reducing engine development time and costs is essential to maintaining U.S. competitiveness in space. The Propulsion Directorate of the Phillips Laboratory has invested in a number of programs to advance liquid rocket engine technology, and several of these are directed at improving design tools for liquid rocket injectors. The purpose of the presentation will be to describe some of these latter programs.

Talley, D. G.↗

NASA NTRS2001

Optical Diagnosis of Gas Turbine Combustors Being Conducted

Researchers at the NASA Glenn Research Center, in collaboration with industry, are reducing gas turbine engine emissions by studying visually the air-fuel interactions and combustion processes in combustors. This is especially critical for next generation engines that, in order to be more fuel-efficient, operate at higher temperatures and pressures than the current fleet engines. Optically based experiments were conducted in support of the Ultra-Efficient Engine Technology program in Glenn's unique, world-class, advanced subsonic combustion rig (ASCR) facility. The ASCR can supply air and jet fuel at the flow rates, temperatures, and pressures that simulate the conditions expected in the combustors of high-performance, civilian aircraft engines. In addition, this facility is large enough to support true sectors ("pie" slices of a full annular combustor). Sectors enable one to test true shapes rather than rectangular approximations of the actual hardware. Therefore, there is no compromise to actual engine geometry. A schematic drawing of the sector test stand is shown. The test hardware is mounted just upstream of the instrumentation section. The test stand can accommodate hardware up to 0.76-m diameter by 1.2-m long; thus sectors or small full annular combustors can be examined in this facility. Planar (two-dimensional) imaging using laser-induced fluorescence and Mie scattering, chemiluminescence, and video imagery were obtained for a variety of engine cycle conditions. The hardware tested was a double annular sector (two adjacent fuel injectors aligned radially) representing approximately 15 of a full annular combustor. An example of the two-dimensional data obtained for this configuration is also shown. The fluorescence data show the location of fuel and hydroxyl radical (OH) along the centerline of the fuel injectors. The chemiluminescence data show C2 within the total observable volume. The top row of this figure shows images obtained at an engine low-power condition, and the bottom row shows data from a higher power operating point. The data show distinctly the differences in flame structure between low-power and high-power engine conditions, in both location and amount of species produced (OH, C2) or consumed (fuel). The unique capability of the facility coupled with its optical accessibility helps to eliminate the need for high-pressure performance extrapolations. Tests such as described here have been used successfully to assess the performance of fuel-injection concepts and to modify those designs, if needed.

Hicks, Yolanda R.↗

NASA NTRS1966

Nonlinear Aspects of Combustion Instability in Liquid Propellant Rocket Motors Sixth Yearly Progress Report, 1 Jun. 1965 - 31 May 1966

This is the sixth yearly report on the research at Princeton University on the problem of combustion instability in liquid-propellant rocket motors. These investigations have been sponsored by the National Aeronautics and Space Administration under NASA Contract NASr-217 and, in the past, under NASA Grant NsG-99-60. The nonlinear aspects of the problem have been emphasized in both the theoretical and experimental portions of the program. Presently, the theoretical research primarily involves studies of possible mechanisms or forcing functions of the instabilities, the nonlinear gasdynamic oscillations associated with instability in rocket motors, the effect of the exhaust nozzle on the stability, and the effect of damping devices on the stability. In conjunction with the theoretical program, an experimental program of an equally broad range is being conducted. This program includes basic experiments both with rocket motors and "cold" chambers which have been designed to study various combustion processes in order to provide understanding which would be useful in the construction of a theoretical model. It also includes studies of the effects of exhaust nozzles and damping devices upon the instability as well as controlled testing of liquid rocket motors with parametric variations intended to determine the factors which strongly influence the incidence of nonlinear combustion instability.

Combustion instability↗

NASA NTRS1975

Suppression of nonlinear oscillations in combustors with partial length acoustic liners

An analytical model is formulated for a three-dimensional nonlinear stability problem in a rocket motor combustion chamber. The chamber is modeled as a right circular cylinder with a short (multi-orifice) nozzle, and an acoustic linear covering an arbitrary portion of the cylindrical periphery. The combustion is concentrated at the injector and the gas flow field is characterized by a mean Mach number. The unsteady combustion processes are formulated using the Crocco time lag model. The resulting equations are solved using a Green's function method combined with numerical evaluation techniques. The influence of acoustic liners on the nonlinear waveforms is predicted. Nonlinear stability limits and regions where triggering is possible are also predicted for both lined and unlined combustors in terms of the combustion parameters.

Espander, W. R.↗

NASA NTRS1991

Simulation of mixing in the quick quench region of a rich burn-quick quench mix-lean burn combustor

A computer program was developed to study the mixing process in the quick quench region of a rich burn-quick quench mix-lean burn combustor. The computer program developed was based on the density-weighted, ensemble-averaged conservation equations of mass, momentum (full compressible Navier-Stokes), total energy, and species, closed by a k-epsilon turbulence model with wall functions. The combustion process was modeled by a two-step global reaction mechanism, and NO(x) formation was modeled by the Zeldovich mechanism. The formulation employed in the computer program and the essence of the numerical method of solution are described. Some results obtained for nonreacting and reacting flows with different main-flow to dilution-jet momentum flux ratios are also presented.

Shih, Tom I.-P.↗

NASA NTRS2000

Active Combustion Control for Aircraft Gas Turbine Engines

Lean-burning combustors are susceptible to combustion instabilities. Additionally, due to non-uniformities in the fuel-air mixing and in the combustion process, there typically exist hot areas in the combustor exit plane. These hot areas limit the operating temperature at the turbine inlet and thus constrain performance and efficiency. Finally, it is necessary to optimize the fuel-air ratio and flame temperature throughout the combustor to minimize the production of pollutants. In recent years, there has been considerable activity addressing Active Combustion Control. NASA Glenn Research Center's Active Combustion Control Technology effort aims to demonstrate active control in a realistic environment relevant to aircraft engines. Analysis and experiments are tied to aircraft gas turbine combustors. Considerable progress has been shown in demonstrating technologies for Combustion Instability Control, Pattern Factor Control, and Emissions Minimizing Control. Future plans are to advance the maturity of active combustion control technology to eventual demonstration in an engine environment.

DeLaat, John C.↗

NASA NTRS1984

Analysis of physical-chemical processes governing SSME internal fluid flows

The efforts to adapt CHAM's computational fluid dynamics code, PHOENICS, to the analysis of flow within the high pressure fuel turbopump (HPFTP) aft-platform seal cavity of the SSME are summarized. In particular, the special purpose PHOENICS satellite and ground station specifically formulated for this application are listed and described, and the preliminary results of the first part two-dimensional analyses are presented and discussed. Planned three-dimensional analyses are also briefly outlined. To further understand the mixing and combustion processes in the SSME fuelside preburners, a single oxygen-hydrogen jet element was investigated.

Singhal, A. K.↗

NASA NTRS1975

Open-loop response of a burning liquid monopropellant

A direct comparison was obtained between the theoretical and experimental response of a burning liquid monopropellant surface to imposed pressure oscillations. The comparison extended beyond the quasi-steady frequency regime into the range where the combustion process interacts with the thermal wave in the liquid phase. The theory considered both gas and liquid-phase transient effects, involving a numerically integrated, first-order perturbation analysis. The experiment employed hydrazine as the test fuel, burning as a strand. With kinetic parameters fixed by steady burning rate measurements, the model gave good predictions of liquid-phase temperature distributions during steady combustion as well as the amplitude and phase of the oscillatory component of the burning rate in the presence of imposed pressure oscillations. The combustion response tends to peak in two frequency ranges; one corresponding to interaction with liquid-phase transient effects, which could be verified both theoretically and experimentally; the second corresponding to gas-phase transient effects, which could only be examined theoretically. Both ranges provide conditions where the amplifying power is sufficient to drive combustion instability.

Allison, C. B.↗

NASA NTRS1972

Effects of rotating flows on combustion and jet noise.

Experimental investigations of combustion in rotating (swirling) flow have shown that the mixing and combustion processes were accelerated, flame length and noise levels significantly decreased, and flame stability increased relative to that obtained without rotation. Unsteady burning accompanied by a pulsating flame, violent fluctuating jet, and intense noise present in straight flow burning were not present in rotating flow burning. Correlations between theory and experiment show good agreement. Such effects due to rotating flows could lead to suppressing jet noise, improving combustion, reducing pollution, and decreasing aircraft engine size. Quantitative analysis of the aero-acoustic relationship and noise source characteristics are needed.-

Schwartz, I. R.↗

NASA NTRS1987

Numerical grid generation and flow simulation in SSME thrust chamber

The development of liquid and solid rocket engines for future space projects demands a detailed optimization process for highly efficient performance and cost reasons. Also, testing of full size engines may not be feasible when the large size requires test facilities which are cost prohibitive or if vacuum operation cannot be acquired. For such situations only scaling from small test scale measurements or accurate analytical predictions will provide the performance prior to actually flying the mission. A rigorous approach for simulating the combustion processes in liquid rocket engines by employing a direct solution of Navier-Stokes equations within the entire volume of the thrust chambers is presented. This method is illustrated in the solution of reactive flow in the Space Shuttle Main Engine (SSME) thrust chamber. The objective is to review recent improvements in the mathematical model and to present the grid generation methodology suitable for rocket thrust chamber geometries.

Gross, K. W.↗

NASA NTRS1999

Design of a Novel Gaseous Hydrogen-Oxygen Rocket Injector Element

NASA and Aerojet are developing a Rocket-Based Combined Cycle (RBCC) engine under the Advanced Reusable Technology program. The rocket application requires that the combustion process be stable, complete, and take place in as short a distance as possible without compromising the structural integrity of the injector itself. A novel gaseous hydrogen-oxygen rocket injector element design was arrived at through an iterative design process making extensive use of CFD simulations, which resulted in a design that is meeting design goals. Sub-scale versions of the injector have been built and tested in a unique test-rig and in a sub-scale RBCC engine. The Aerojet RBCC concept integrates small rocket thrusters into the rearfacing base area of struts placed in the flowpath of a scramjet (Supersonic Combusting Ramjet) engine. In one mode of operation, at vehicle takeoff, the rockets provide the primary thrust with additional thrust coming from an ejector effect as air is drawn into the engine inlet, entrained, and accelerated by the rocket exhaust.

Glenn, Dennis E.↗

NASA NTRS2003

Catalyzed Combustion In Micro-Propulsion Devices: Project Status

In recent years, there has been a tendency toward shrinking the size of spacecraft. New classes of spacecraft called micro-spacecraft have been defined by their mass, power, and size ranges. Spacecraft in the range of 20 to 100 kg represent the class most likely to be utilized by most small sat users in the near future. There are also efforts to develop 10 to 20 kg class spacecraft for use in satellite constellations. More ambitious efforts will be to develop spacecraft less than 10 kg, in which MEMS fabrication technology is required. These new micro-spacecraft will require new micro-propulsion technology. Although micro-propulsion includes electric propulsion approaches, the focus of this proposed program is micro-chemical propulsion which requires the development of microcombustors. As combustors are scaled down, the surface to volume ratio increases. The heat release rate in the combustor scales with volume, while heat loss rate scales with surface area. Consequently, heat loss eventually dominates over heat release when the combustor size becomes smaller, thereby leading to flame quenching. The limitations imposed on chamber length and diameter has an immediate impact on the degree of miniaturization of a micro-combustor. Before micro-combustors can be realized, such a difficulty must be overcome. One viable combustion alternative is to take advantage of surface catalysis. Micro-chemical propulsion for small spacecraft can be used for primary thrust, orbit insertion, trajectory-control, and attitude control. Grouping micro-propulsion devices in arrays will allow their use for larger thrust applications. By using an array composed of hundreds or thousands of micro-thruster units, a particular configuration can be arranged to be best suited for a specific application. Moreover, different thruster sizes would provide for a range of thrust levels (from N s to mN s) within the same array. Several thrusters could be fired simultaneously for thrust levels higher than the basic units, or in a rapid sequence in order to provide gradual but steady low-g acceleration. These arrays of micro-propulsion systems would offer unprecedented flexibility and redundancy for satellite propulsion and reaction control for launch vehicles. A high-pressure bi-propellant micro-rocket engine is already being developed using MEMS technology. High pressure turbopumps and valves are to be incorporated onto the rocket chip . High pressure combustion of methane and O2 in a micro-combustor has been demonstrated without catalysis, but ignition was established with a spark. This combustor has rectangular dimensions of 1.5 mm by 8 mm (hydraulic diameter 3.9 mm) and a length of 4.5 mm and was operated at 1250 kPa with plans to operate it at 12.7 MPa. These high operating pressures enable the combustion process in these devices, but these pressures are not practical for pressure fed satellite propulsion systems. Note that the use of these propellants requires an ignition system and that the use of a spark would impose a size limitation to this micro-propulsion device because the spark unit cannot be shrunk proportionately with the thruster. Results presented in this paper consist of an experimental evaluation of the minimum catalyst temperature for initiating/supporting combustion in sub-millimeter diameter tubes. The tubes are resistively heated and reactive premixed gases are passed through the tubes. Tube temperature and inlet pressure are monitored for an indication of exothermic reactions and composition changes in the gases.

Sung, C. J.↗

NASA NTRS1986

Thermodynamics and combustion modeling

Modeling fluid phase phenomena blends the conservation equations of continuum mechanics with the property equations of thermodynamics. The thermodynamic contribution becomes especially important when the phenomena involve chemical reactions as they do in combustion systems. The successful study of combustion processes requires (1) the availability of accurate thermodynamic properties for both the reactants and the products of reaction and (2) the computational capabilities to use the properties. A discussion is given of some aspects of the problem of estimating accurate thermodynamic properties both for reactants and products of reaction. Also, some examples of the use of thermodynamic properties for modeling chemically reacting systems are presented. These examples include one-dimensional flow systems and the internal combustion engine.

Zeleznik, Frank J.↗

NASA NTRS1993

Collisional excitation of CO by H2O - An astrophysicist's guide to obtaining rate constants from coherent anti-Stokes Raman line shape data

Rate constants for excitation of CO by collisions with H2O are needed to understand recent observations of comet spectra. These collision rates are closely related to spectral line shape parameters, especially those for Raman Q-branch spectra. Because such spectra have become quite important for thermometry applications, much effort has been invested in understanding this process. Although it is not generally possible to extract state-to-state rate constants directly from the data as there are too many unknowns, if the matrix of state-to-state rates can be expressed in terms of a rate-law model which depends only on rotational quantum numbers plus a few parameters, the parameters can be determined from the data; this has been done with some success for many systems, especially those relevant to combustion processes. Although such an analysis has not yet been done for CO-H2O, this system is expected to behave similarly to N2-H2O which has been well studies; modifications of parameters for the latter system are suggested which should provide a reasonable description of rate constants for the former.

Green, Sheldon↗

NASA NTRS1989

Microgravity combustion science: A program overview

The promise of microgravity combustion research is introduced by way of a brief survey of results, the available set of reduced gravity facilities, and plans for experimental capabilities in the Space Station era. The study of fundamental combustion processes in a microgravity environment is a relatively new scientific endeavor. A few simple, precursor experiments were conducted in the early 1970's. Today the advent of the U.S. space shuttle and the anticipation of the Space Station Freedom provide for scientists and engineers a special opportunity, in the form of long duration microgravity laboratories, and need, in the form of spacecraft fire safety and a variety of terrestrial applications, to pursue fresh insight into the basic physics of combustion. The microgravity environment enables a new range of experiments to be performed since buoyancy-induced flows are nearly eliminated, normally obscured forces and flows may be isolated, gravitational settling or sedimentation is nearly eliminated, and larger time or length scales in experiments become permissible. The range of experiments completed to date was not broad, but is growing. Unexpected phenomena have been observed often in microgravity combustion experiments, raising questions about the degree of accuracy and completion of our classical understanding and our ability to estimate spacecraft fire hazards. Because of the field's relative immaturity, instrumentation has been restricted primarily to high-speed photography. To better explain these findings, more sophisticated diagnostic instrumentation, similar to that evolving in terrestrial laboratories, is being developed for use on Space Station Freedom and, along the way, in existing microgravity facilities.

Source record↗

NASA NTRS1993

Overview of NASA's microgravity combustion science and fire safety program

The study of fundamental combustion processes in a microgravity environment is a relatively new scientific endeavor. A few simple, precursor experiments were conducted in the early 1970's. Today the advent of the U.S. space shuttle and the anticipation of the Space Station Freedom provide for scientists and engineers a special opportunity -- in the form of long duration microgravity laboratories -- and need -- in the form of spacecraft fire safety and a variety of terrestrial applications -- to pursue fresh insight into the basic physics of combustion. Through microgravity, a new range of experiments can be performed since: (1) Buoyancy-induced flows are nearly eliminated; (2) Normally obscured forces and flows may be isolated; (3) Gravitational settling or sedimentation is nearly eliminated; and (4) Larger time or length scales in experiments become permissible.

Ross, Howard D.↗

NASA NTRSDate not supplied

TPSAS-NF1676L-32577-DND

The ground testing of hypersonic vehicles requires the replication of the flow conditions at high speed and altitude. To produce these flow conditions, stored compressed air is expanded through a convergent-divergent nozzle to produce the required pressures and speed. However, the expansion process also cools the air, and so to match the flight temperatures, some form of heating needs to be employed. Vitiated heating is a common method, where the air is heated by burning fuel in the low speed side of the nozzle, and then oxygen is added to bring the level of O2 up to match that of standard air. The resulting flow no longer has the same composition as standard air, (except for the oxygen level), but rather contains combustion products, often referred to as vitiates as part of the mixture. The presence of these vitiates in the flow effects the wind tunnel test conditions. For example, the specific heat and molecular density are changed, the kinetics of combustion are altered and the flow features in the test article are altered. In this talk, the effects of the vitiates on the testing conditions and on the performance of test articles is described. Specific examples include the effects of molecular density on the flow, how combustion processes are altered by the presence of vitiates and how condensation of vitiates can alter the test conditions. In addition, the effect of the less common vitiates produced by arc-heated tunnels are mentioned, such as NO, non-thermal equilibrium and the presence of copper solids in the flow. Finally some thoughts on how large an effect these vitiates have on the test results are presented.

Andrew T Norris↗

NASA NTRS1993

Combustion for future supersonic transport propulsion

Even with it's marginal performance, Concorde has demonstrated that supersonic civil aircraft are a practical proposition. A second generation machine will need sufficiently good performance for a robust operating system that can provide reliable, frequent service with competitive economics. Additionally, the propulsion system must be acceptable environmentally. That is it must create acceptable noise levels around airports and have acceptable emissions throughout its mission including cruise. Whatever devices may be used to improve the acceptability at subsonic flight conditions, the high operating temperatures at cruise can create difficult targets for the operation of the combustion system both mechanically and in the combustion process itself. While the driving force is ever better fuel consumption and weight to achieve economic viability, a future supersonic transport engine will have cycle temperatures limited only by the mechanical integrity of the major components. The environment of the major components in modern gas turbine engines is dominated by the air delivered by the compressor system. Consequently the maximum compression temperature is governed by materials available for the turbine and compressor discs. The continued improvement of the disc material leads to combustion inlet temperatures beyond today's experience and sets difficult targets for combustion system emissions. This is worsened by the requirement being at cruise and therefore maintained for the major part of the mission. Problems such as creep and oxidation of metallic parts are also considered.

B. W. Lowrie↗