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NASA NTRS1997

Strain-Rate-Free Diffusion Flames: Initiation, Properties, and Quenching

For about a half century, the stabilization of a steady planar deflagration on a heat-sink-type flat-flame burner has been of extraordinary service for the theoretical modeling and diagnostic probing of combusting gaseous mixtures. However, most engineering devices and most unwanted fire involve the burning of initially unmixed reactants. The most vigorous burning of initially separated gaseous fuel and oxidizer is the diffusion flame. In this useful idealization (limiting case), the reactants are converted to product at a mathematically thin interface, so no interpenetration of fuel and oxidizer occurs. This limit is of practical importance because it often characterizes the condition of optimal performance (and sometimes environmentally objectionable operation) of a combustor. A steady planar diffusion flame is most closely approached in the laboratory in the counterflow apparatus. The utility of this simple-strain-rate flow for the modeling and probing of diffusion flames was noted by Pandya and Weinberg 35 years ago, though only in the last decade or so has its use become internationally common place. However, typically, as the strain rate a is reduced below about 20 cm(exp -1), and the diffusion-flame limit (reaction rate much faster than the flow rate) is approached, the burning is observed to become unstable in earth gravity. The advantageous steady planar flow is not available in the diffusion-flame limit in earth gravity. This is unfortunate because the typical spatial scale in a counterflow is (k/a)(sup 1/2), where k denotes a characteristic diffusion coefficient; thus, the length scale becomes large, and the reacting flow is particularly amenable to diagnostic probing, as the diffusion-flame limit is approached. The disruption of planar symmetry is owing the fact that, as the strain rate a decreases, the residence time (l/a) of the throughput in the counterflow burner increases. Observationally, when the residence time exceeds about 50 msec, the inevitably present convective (Rayleigh-Benard) instabilities, associated with hot-under-cold (flame-under-fresh-reactant) stratification of fluid in a gravitational field, have time to grow to finite amplitude during transit of the burner.

Fendell, Francis↗

NASA NTRS2001

Some Recent Observations on the Burning of Isolated N-Heptane and Alcohol Droplets

In a joint program involving Prof. F.A. Williams of the University of California, San Diego and Dr. V. Nayagam of the National Center for Microgravity Research on Combustion and Fluid Dynamics, the combustion of liquid fuel droplets of n-heptane, n-decane, methanol, methanol-water, ethanol and ethanol-water having initial diameters between about 1 mm and 6 mm continues to be studied. The objectives of the work are to improve fundamental knowledge of droplet combustion dynamics for pure fuels and fuel-water mixtures through microgravity experiments and theoretical analyses. The Princeton contributions to the collaborative program supports the engineering design, data analysis, and data interpretation requirements for the study of initially single component, spherically symmetric, isolated droplet combustion studies through experiments and numerical modeling. The complementary UCSD contributions apply asymptotic theoretical analyses and are described in the published literature and in a companion communication in this conference. The combined program continues to focus on analyses of results obtained from Fiber Supported Droplet Combustion (FSDC) experiments (FSDC-2, STS- 94) conducted with the above fuels in shuttle cabin air and Droplet Combustion Experiment (DCE) data obtained for unsupported and fiber supported droplets of n-heptane in Helium-Oxygen mixtures and cabin air (STS-83, STS-94). The program is preparing for a second DCE experimental mission using methanol/methanol-water as fuels and helium-oxygen-nitrogen environments. DCE-2 is to be conducted aboard the International Space Station. Emphases of recent Princeton work are on the study of simple alcohols (methanol, ethanol) and alcohol/water mixtures as fuels, with time-dependent measurements of drop size, flame-standoff, liquid-phase composition, and finally, extinction. Ground based experiments have included bench-scale studies at Princeton and collaborative experimental studies in the 2.2 second drop tower at NASA-Glenn Research Center.

Dryer, F. L.↗

NASA NTRS2010

Liquid Oxygen/Liquid Methane Component Technology Development at MSFC

The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LOX)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon exploration studies. The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. Besides existing in-house risk reduction activities, NASA has solicited from industry their participation on component technologies based on the potential application to the lunar ascent main engine (AME). Contracted and NASA efforts have ranged from valve technologies to engine system testbeds. The application for the AME is anticipated to be an expendable, pressure-fed engine for ascent from the moon at completion of its lunar stay. Additionally, the hardware is expected to provide an abort capability prior to landing, in the event that descent systems malfunction. For the past 4 years, MSFC has been working with the Glenn Research Center and the Johnson Space Center on methane technology development. This paper will focus on efforts specific to MSFC in pursuing ignition, injector performance, chamber material assessments and cryogenic valve technologies. Ignition studies have examined characteristics for torch, spark and microwave systems. Injector testing has yielded insight into combustion performance for shear, swirl and impinging type injectors. The majority of chamber testing has been conducted with ablative and radiatively cooled chambers with planned activities for regenerative and transpiration cooled chambers. Lastly, an effort is underway to examine the long duration exposure issues of cryogenic valve internal components. The paper will summarize the status of these efforts.

Robinson, Joel W.↗

NASA NTRS2016

Impact of Flight Enthalpy, Fuel Simulant, and Chemical Reactions on the Mixing Characteristics of Several Injectors at Hypervelocity Flow Conditions

The high total temperatures or total enthalpies required to duplicate the high-speed flight conditions in ground experiments often place stringent requirements on the material selection and cooling needs for the test articles and intrusive flow diagnostic equipment. Furthermore, for internal flows, these conditions often complicate the use of nonintrusive diagnostics that need optical access to the test section and interior portions of the flowpath. Because of the technical challenges and increased costs associated with experimentation at high values of total enthalpy, an attempt is often made to reduce it. This is the case for the Enhanced Injection and Mixing Project (EIMP) currently underway in the Arc-Heated Scramjet Test Facility at the NASA Langley Research Center. The EIMP aims to investigate supersonic combustion ramjet (scramjet) fuel injection and mixing physics, improve the understanding of underlying physical processes, and develop enhancement strategies and functional relationships between mixing performance and losses relevant to flight Mach numbers greater than 8. The experiments will consider a "direct-connect" approach and utilize a Mach 6 nozzle to simulate the combustor entrance flow of a scramjet engine. However, while the value of the Mach number is matched to that expected at the combustor entrance in flight, the maximum value of the total enthalpy for these experiments is limited by the thermal-structural limits of the uncooled experimental hardware. Furthermore, the fuel simulant is helium, not hydrogen. The use of "cold" flows and non-reacting mixtures of fuel simulants for mixing experiments is not new and has been extensively utilized as a screening technique for scramjet fuel injectors. In this study, Reynolds-averaged simulations are utilized (RAS) to systematically verify the implicit assumptions used by the EIMP. This is accomplished by first performing RAS of mixing for two injector configurations at planned nominal experimental conditions. The mixing parameters of interest, such as mixing efficiency and total pressure recovery, are then computed and compared to the values obtained from RAS under the true enthalpy conditions and using helium and hydrogen. Finally, the impact of combustion on mixing, often deemed small enough to neglect at hypervelocity conditions, is assessed by comparing the results obtained from the hydrogen-fueled reacting and non-reacting RAS. For reacting flows, in addition to mixing efficiency and total pressure recovery, the combustion efficiency and thrust potential are also considered. In all of the simulations, the incoming air Mach number and the fuel-to-air ratio are the same, while the total pressure, total enthalpy, and the fuel simulant vary depending on the case considered. It is found that under some conditions the "cold" flow experiments are a good approximation of the flight.

Drozda, Tomasz G.↗

NASA NTRS1963

Ninth Symposium (International) on Combustion

The Ninth Symposium (International) on Combustion was held at Cornell University, Ithaca, New York, August 27 to September 1, 1962, under the auspices of the Combustion Institute. Registration was in excess of 600, with more than 100 attending from Australia, Belgium, Canada, France, Germany, Great Britain, Hungary, Israel, Italy, Japan, Netherlands, Spain and Sweden. Over 200 papers were submitted for consideration, of which 121 were placed on the program and 108 printed in the Proceedings. Two Discussions (Detonations, organized by Dr. D. R. White, General Electric Research Laboratory; Fundamental Flame Processes, organized by Dr. W. H. Avery, APL/The Johns Hopkins University) occupied 4 half-day sessions each. Preprints of all Discussions papers were available several weeks prior to the Symposium. Three Colloquia (Modeling Principles, organized by Professor D. 13. Spalding, Imperial College; Reactions and Phase Changes in Supersonic Plow, organized by Professor P. P. Wegener, Yale University; Reciprocating Engine Combustion Research, organized by Professor E. S. Starkman, University of California) occupied 2 or 3 half-day sessions each. Contributed Papers in many areas of the combustion field were presented in 10 half-day sessions. Comments on nearly every paper are included in the Proceedings.

Gas phase↗

NASA NTRS2004

Advanced Manufacturing Techniques Demonstrated for Fabricating Developmental Hardware

NASA Glenn Research Center's Engineering Development Division has been working in support of innovative gas turbine engine systems under development by Glenn's Combustion Branch. These one-of-a-kind components require operation under extreme conditions. High-temperature ceramics were chosen for fabrication was because of the hostile operating environment. During the designing process, it became apparent that traditional machining techniques would not be adequate to produce the small, intricate features for the conceptual design, which was to be produced by stacking over a dozen thin layers with many small features that would then be aligned and bonded together into a one-piece unit. Instead of using traditional machining, we produced computer models in Pro/ENGINEER (Parametric Technology Corporation (PTC), Needham, MA) to the specifications of the research engineer. The computer models were exported in stereolithography standard (STL) format and used to produce full-size rapid prototype polymer models. These semi-opaque plastic models were used for visualization and design verification. The computer models also were exported in International Graphics Exchange Specification (IGES) format and sent to Glenn's Thermal/Fluids Design & Analysis Branch and Applied Structural Mechanics Branch for profiling heat transfer and mechanical strength analysis.

Redding, Chip↗

NASA NTRS1949

Altitude Performance and Operational Characteristics of 29-inch-diameter Tail-pipe Burner with Several Fuel Systems and Flame Holders on J35 Turbojet Engine

An investigation of turbojet-engine thrust augmentation by means of tail-pipe burning has been conducted in the NACA Lewis altitude wind tunnel. Several fuel systems and flame holders were investigated in a 29-inch-diameter tail-pipe burner to determine the effect of fuel distribution and flame-holder design on tail-pipe-burner performance and operational characteristics over a range of simulated flight conditions. At an altitude of 5000 feet, the type of flame holder used had only a slight effect on the combustion efficiency. As the altitude was increased, the decrease in peak combustion efficiency became more rapid as the blocking area of the flame holder was reduced. At all altitudes investigated, an improvement in the uniformity of the radial distribution of fuel and air slightly increased the peak combustion efficiencies and shifted the peak combustion efficiency to higher tail-pipe fuel-air ratios. The use of an internal cooling liner extending the full length of the tail-pipe combustion chamber provided adequate shell cooling at all flight conditions investigated.

Conrad, E William↗

NASA NTRS1951

Internal Flow and Burning Characteristics of 16-inch Ram Jet Operating in a Free Jet at Mach Numbers of 1.35 and 1.73

The effects of mass-flow ratio on the additive drag and normal-shock position of a single oblique-shock diffuser are presented. Also evaluated is the variation with operating condition of the velocity distribution at the combustion-chamber inlet. A comparison with connected-pipe data is included. Burner performance with a corrugated gutter-grid flame holder is discussed. It is shown that the total-pressure drop across the combustion chamber can be predicted with reasonable accuracy from the computed flame holder and combustion momentum pressure losses.

DIFFUSERS, SUPERSONIC↗

NASA NTRS1998

Advanced Non-Intrusive Instrumentation for Propulsion Engines

Changes in engine technology such as higher temperatures, higher tip speeds, new metal/composite/ceramic materials together with radical changes in design philosophy will require amongst other prerequisites the ability to measure and to monitor key internal gas and structural characteristics. The symposium papers presented non-intrusive measurement and analysis technologies in the following categories: Laser Point Measurements (11); Absorption and Infrared Techniques (4); Paints - Surface Sensors (6); Laser Induced Fluorescence (6); Mechanical (7); Films (5); Laser Planar Measurement (9); and a Keynote Address.

Propulsion↗

NASA NTRS1998

Research and Technology 1997

NASA Lewis Research Center is responsible for developing and transferring critical technologies that address national priorities in aeropropulsion and space applications in partnership with U.S. industries, universities, and Government institutions. As NASA s designated Lead Center for Aeropropulsion, our role is to develop, verify, and transfer aeropropulsion technologies to U.S. industry. As NASA s designated Center of Excellence in Turbomachinery, our role is to develop new and innovative turbomachinery technology to improve the reliability, performance, efficiency and affordability, capacity, and environmental compatibility of future aerospace vehicles. We also maintain a science and technology development role in aeropropulsion, communications, space power and onboard propulsion, and microgravity fluid physics and combustion. We are committed to enabling non-aerospace U.S. industries to benefit directly from the technologies developed through our programs to maximize the benefit to the Nation and the return on each taxpayer s investment. In addition, we are aggressively pursuing continuous improvement in our management and business practices and striving for diversity in our workforce as together we push the edge of technology in space and aeronautics. The Lewis Research Center is a unique facility located in an important geographical area, the southwest corner of Cleveland, Ohio. Situated on 350 acres of land adjacent to the Cleveland Hopkins International Airport, Lewis comprises more than 140 buildings that include 24 major facilities and over 500 specialized research and test facilities. Additional facilities are located at Plum Brook Station, which is about 50 miles west of Cleveland. Over 3700 people staff Lewis, including civil service employees and support service contractors. Over half of them are scientists and engineers, who plan, conduct or oversee, and report on our research tasks and projects. They are assisted by technical specialists, skilled workers, and an administrative staff. Our end product is knowledge. This report is designed to help us make this knowledge fully available to potential users the aircraft engine industry, the energy industry, the automotive industry, the aerospace industry, and others. It is organized so that a broad cross section of the community can readily use it. Each article begins with a short introductory paragraph that should prove to be a valuable tool for the layperson. These articles summarize the progress made during the year in various technical areas and portray the technical and administrative support associated with Lewis technology programs. We hope that the information is useful to all. If additional information is desired, readers are encouraged to contact the researchers identified in the articles and to visit Lewis on the World Wide Web (http://www.lerc.nasa.gov/). This document is available on the World Wide Web (http://www.lerc.nasa.gov/WWW/RT).

Source record↗

NASA NTRS2014

Additive Manufacturing Design Considerations for Liquid Engine Components

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Whitten, Dave↗

NASA NTRS1997

Requirements and Development of an Acceleration Measurement System for International Space Station Microgravity Science Payloads

The International Space Station is being developed by NASA and international partners as a versatile user platform to allow long term on-orbit investigations of a variety of scientific and technology arenas. In particular, scientific studies are planned within a research class known as microgravity science in areas such as biotechnology, combustion, fluid physics, and materials sciences. An acceleration measurement system is in development to aid such research conducted in the on-orbit conditions of apparent weightlessness. This system provides a general purpose acceleration measurement capability in support of these payloads and investigators. Such capability allows for systematic study of scientific phenomena by obtaining information regarding the local accelerations present during experiment operations. Preparations for implementing this flight measurement system involves two distinct stages: requirements development prior to initiating the design activity, and the design activity itself. This paper defines the requirements definition approach taken, provides an overview of the results of the requirements phase, and outlines the initial design considerations being addressed for this measurement system. Some preliminary engineering approaches are also described.

Sutliff, Thomas J.↗

NASA NTRS2019

Transfer-Function Determination for Infinite-Tube-Probe Pressure Transducers with Application to Turbofan Core/Combuster Noise

Turbofan hot-section unsteady pressure measurements are complicated by environmental limitations of current-generation sensors. Accurate direct measurements are normally not possible and engine-external measurement techniques, using sufficiently long sense lines, are utilized instead. Remote measurement comes at a cost, however, as it introduces a magnitude reduction within the line as well as a phase lag relative to the desired engine-internal measurement location. Determination, or validation, of a transfer function relating the engine internal pressure to the observed remote value is necessary. Transfer functions are examined for various configurations of the so-called infinite-tube-probe arrangement in order to optimize measurement performance. The experimental setup uses a normal-incidence tube that ordinarily is utilized for impedance eduction. Here, its downstream end instead is made up of a hard-wall termination instrumented with a flush-mounted microphone and a Kulite pressure transducer as well as a sense line connection. This allows the remote and direct measurements to be related under controlled conditions. Transfer-function measurements are presented and compared to predictions for several parametric variations.

Turbomachinery Noise↗

NASA NTRS2011

Shuttle Propulsion System Major Events and the Final 22 Flights

Numerous lessons have been documented from the Space Shuttle Propulsion elements. Major events include loss of the Solid Rocket Boosters (SRB's) on STS-4 and shutdown of a Space Shuttle Main Engine (SSME) during ascent on STS-51F. On STS-112 only half the pyrotechnics fired during release of the vehicle from the launch pad, a testament for redundancy. STS-91 exhibited freezing of a main combustion chamber pressure measurement and on STS-93 nozzle tube ruptures necessitated a low liquid level oxygen cut off of the main engines. A number of on pad aborts were experienced during the early program resulting in delays. And the two accidents, STS-51L and STS-107, had unique heritage in history from early program decisions and vehicle configuration. Following STS-51L significant resources were invested in developing fundamental physical understanding of solid rocket motor environments and material system behavior. And following STS-107, the risk of ascent debris was better characterized and controlled. Situational awareness during all mission phases improved, and the management team instituted effective risk assessment practices. The last 22 flights of the Space Shuttle, following the Columbia accident, were characterized by remarkable improvement in safety and reliability. Numerous problems were solved in addition to reduction of the ascent debris hazard. The Shuttle system, though not as operable as envisioned in the 1970's, successfully assembled the International Space Station (ISS). By the end of the program, the remarkable Space Shuttle Propulsion system achieved very high performance, was largely reusable, exhibited high reliability, and was a heavy lift earth to orbit propulsion system. During the program a number of project management and engineering processes were implemented and improved. Technical performance, schedule accountability, cost control, and risk management were effectively managed and implemented. Award fee contracting was implemented to provide performance incentives. The Certification of Flight Readiness and Mission Management processes became very effective. A key to the success of the propulsion element projects was related to relationships between the MSFC project office and support organizations with their counterpart contractor organizations. The teams worked diligently to understand and satisfy requirements and achieve mission success.

Owen, James W.↗

NASA NTRS2007

Restricted Modal Analysis Applied to Internal Annular Combustor Autospectra and Cross-Spectra Measurements

A treatment of the modal decomposition of the pressure field in a combustor as determined by two pressure time history measurements is developed herein. It is applied to a Pratt and Whitney PW4098 engine combustor over a range of operating conditions. For modes other than the plane wave the assumption is made that there are distinct frequency bands in which the individual modes, including the plane wave mode, overlap such that if circumferential mode m and circumferential mode m-1 are present then circumferential mode m-2 is not. In the analysis used herein at frequencies above the first cutoff mode frequency, only pairs of circumferential modes are individually present at each frequency. Consequently, this is a restricted modal analysis. As part of the analysis one specifies mode cut-on frequencies. This creates a set of frequencies that each mode spans. One finding was the successful use of the same modal span frequencies over a range of operating conditions for this particular engine. This suggests that for this case the cut-on frequencies are in proximity at each operating condition. Consequently, the combustion noise spectrum related to the circumferential modes might not change much with operating condition.

Miles, Jeffrey Hilton↗

NASA NTRS2003

High-Flow Jet Exit Rig Designed and Fabricated

The High-Flow Jet Exit Rig at the NASA Glenn Research Center is designed to test single flow jet nozzles and to measure the appropriate thrust and noise levels. The rig has been designed for the maximum hot condition of 16 lbm/sec of combustion air at 1960 R (maximum) and to produce a maximum thrust of 2000 lb. It was designed for cold flow of 29.1 lbm/sec of air at 530 R. In addition, it can test dual-flow nozzles (nozzles with bypass flow in addition to core flow) with independent control of each flow. The High- Flow Jet Exit Rig was successfully fabricated in late 2001 and is being readied for checkout tests. The rig will be installed in Glenn's Aeroacoustic Propulsion Laboratory. The High-Flow Jet Exit Rig consists of the following major components: a single component force balance, the natural-gas-fueled J-79 combustor assembly, the plenum and manifold assembly, an acoustic/instrumentation/seeding (A/I/S) section, a table, and the research nozzles. The rig will be unique in that it is designed to operate uncooled. The structure survives the 1960 R test condition because it uses carefully selected high temperature alloy materials such as Hastelloy-X. The lower plenum assembly was designed to operate at pressures to 450 psig at 1960 R, in accordance with the ASME B31.3 piping code. The natural gas-fueled combustor fires directly into the lower manifold. The hot air is directed through eight 1-1/2-in. supply pipes that supply the upper plenum. The flow is conditioned in the upper plenum prior to flowing to the research nozzle. The 1-1/2-in. supply lines are arranged in a U-shaped design to provide for a flexible piping system. The combustor assembly checkout was successfully conducted in Glenn's Engine Component Research Laboratory in the spring of 2001. The combustor is a low-smoke version of the J79 combustor used to power the F4 Phantom military aircraft. The natural gas-fueled combustor demonstrated high-efficiency combustion over a wide range of operating conditions. This wide operating envelope is required to support the testing of both single- and dual-flow nozzles. Key research goals include providing simultaneous, highly accurate acoustic, flow, and thrust measurements on jet nozzle models in realistic flight conditions, as well as providing scaleable acoustic results. The High-Flow Jet Exit Rig is a second-generation high-flow test rig. Improvements include cleaner flow with reduced levels of particulate, soot, and odor. Choked-flow metering is required with plus or minus 0.25-percent accuracy. Thrust measurements from 0 to 2000 lbf are required with plus or minus 0.25-percent accuracy. Improved acoustics will be achieved by minimizing noise through large pipe bend radii, lower internal flow velocities, and microdrilled choke plates with thousands of 0.040-in.- diameter holes.

Buehrle, Robert J.↗

NASA NTRS2019

Extreme-Temperature Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

The United States (US) National Aeronautics and Space Administration (NASA) and its US industry partners are developing extreme-temperature composite nozzle extensions for a variety of cryogenic liquid rocket engine propulsion systems. Applications under consideration at the NASA Marshall Space Flight Center (MSFC) include launch vehicle (upper stage), in-space, and lunar lander descent/ascent propulsion systems. Composite material systems of interest include carbon-carbon (C-C) and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Missions addressed include access to low Earth orbit, the lunar surface, and more distant destinations. Cryogenic upper-stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. As a result of the large size of such nozzles, and the related engine performance requirements, composite nozzle extensions are being considered to reduce mass impacts. Currently, metallic and foreign composite nozzle extensions used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles represent the state-of-the-art. Such extensions are limited to use at or slightly above 2000°F (1093°C). Materials under development by MSFC and its industry partners have the potential to operate at temperatures up to (or above) 4250°F (2343°C). Marshall Space Flight Center efforts are aimed at (a) further developing the technology and databases needed to enable the use of composite nozzle extensions on cryogenic liquid rocket engines, (b) developing and demonstrating low-cost capabilities for testing and qualifying such nozzle extensions, and (c) advancing the US domestic supply chain for nozzle extensions. Through the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Programs, low-level internal MSFC research projects, and teaming arrangements with domestic industry partners, composite material design, development, hot-fire test, and evaluation efforts are progressing. Hot- fire engine tests of subscale hardware have been conducted using oxygen/hydrogen (LOX/H2), oxygen/methane (LOX/CH4), and oxygen/kerosene (LOX/RP-1) propellants. These engine tests at MSFC have enabled the evaluation of both heritage and state-of-the-art material systems, demonstrating the initial capabilities of the extreme temperature materials and their fabrication methods. Recent, ongoing, and potential future work supporting cryogenic propulsion systems development will be presented. The composite nozzle extension technology and test capabilities being developed are intended to support both NASA and US Department of Defense requirements, as well as those of the broader Commercial Space industry.

Valentine, Peter G.↗

NASA NTRS2000

Turbine Airfoil With CMC Leading-Edge Concept Tested Under Simulated Gas Turbine Conditions

Silicon-based ceramics have been proposed as component materials for gas turbine engine hot-sections. When the Navy s Harrier fighter experienced engine (Pegasus F402) failure because of leading-edge durability problems on the second-stage high-pressure turbine vane, the Office of Naval Research came to the NASA Glenn Research Center at Lewis Field for test support in evaluating a concept for eliminating the vane-edge degradation. The High Pressure Burner Rig (HPBR) was selected for testing since it could provide temperature, pressure, velocity, and combustion gas compositions that closely simulate the engine environment. The study focused on equipping the stationary metal airfoil (Pegasus F402) with a ceramic matrix composite (CMC) leading-edge insert and evaluating the feasibility and benefits of such a configuration. The test exposed the component, with and without the CMC insert, to the harsh engine environment in an unloaded condition, with cooling to provide temperature relief to the metal blade underneath. The insert was made using an AlliedSignal Composites, Inc., enhanced HiNicalon (Nippon Carbon Co. LTD., Yokohama, Japan) fiber-reinforced silicon carbide composite (SiC/SiC CMC) material fabricated via chemical vapor infiltration. This insert was 45-mils thick and occupied a recessed area in the leading edge and shroud of the vane. It was designed to be free floating with an end cap design. The HPBR tests provided a comparative evaluation of the temperature response and leading-edge durability and included cycling the airfoils between simulated idle, lift, and cruise flight conditions. In addition, the airfoils were aircooled, uniquely instrumented, and exposed to the exact set of internal and external conditions, which included gas temperatures in excess of 1370 C (2500 F). In addition to documenting the temperature response of the metal vane for comparison with the CMC, a demonstration of improved leading-edge durability was a primary goal. First, the metal vane was tested for a total of 150 cycles. Both the leading edge and trailing edge of the blade exhibited fatigue cracking and burn-through similar to the failures experienced in service by the F402 engine. Next, an airfoil, fitted with the ceramic leading edge insert, was exposed for 200 cycles. The temperature response of those HPBR cycles indicated a reduced internal metal temperature, by as much as 600 F at the midspan location for the same surface temperature (2100 F). After testing, the composite insert appeared intact, with no signs of failure on either the vane s leading or trailing edge. Only a slight oxide scale, as would be expected, was noted on the insert. Overall, the CMC insert performed similarly to a thick thermal barrier coating. With a small air gap between the metal and the SiC/SiC leading edge, heat transfer from the CMC to the metal alloy was low, effectively lowering the temperatures. The insert's performance has proven that an uncooled CMC can be engineered and designed to withstand the thermal up-shock experienced during the severe lift conditions in the Pegasus engine. The design of the leading-edge insert, which minimized thermal stresses in the SiC/SiC CMC, showed that the CMC/metal assembly can be engineered to be a functioning component.

Robinson, R. Craig↗