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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1959

Analysis of Flow-System Starting Dynamics of Turbopump-Fed Liquid-Propellant Rocket

Two rocket configurations with turbopump drive were investigated analytically. In one configuration the inlet pressure to the turbine was fixed at the design value. The second configuration employed a "bootstrap" technique for supplying energy to the turbine. An injector was the chief resistance between the pump and the rocket combustion chamber. From the analysis two parameters were developed from which the speed response time of the turbopump, the flow response time, and the maximum dynamic line loss could be evaluated. These parameters were functions of turbopump moment of inertia, design performance of the turbine, and flow-system geometry. The moment of inertia of the turbopump and the ratio of turbine torque at zero speed to design torque had the most influence on the starting dynamics of the flow system. These parameters were also applicable to the bootstrap configuration as long as the inlet pressure to the turbine exceeded half the design value.

Krebs, Richard P.↗
NASA NTRS1999

Numerical Prediction of Transient Axial Thrust and Internal Flows in a Rocket Engine Turbopump

This paper presents the application of the Generalized Fluid System Simulation Program (GFSSP) to model the time-dependent flow in a complex secondary flow circuit of the turbopump of the Fastrac engine currently under development at Marshall Space Flight Center. GFSSP is a general purpose computer program for analyzing steady-state and time-dependant flowrates, pressures, temperatures, and concentrations in a complex flow network. The program employs a finite volume formulation of mass, momentum and energy conservation equations in conjunction with the thermodynamic equation of state of real fluids. GFSSP was used to calculate the axial thrust and internal flow distribution of the Fastrac engine turbopump during the start and shut down transients. The models discussed in this paper use boundary conditions that were extracted from turbopump test data. The GFSSP predicted turbopump secondary flow passage pressures and temperatures were compared with actual measured values.

VanHooser, Katherine↗
NASA NTRS2001

A Three Dimensional Parallel Time Accurate Turbopump Simulation Procedure Using Overset Grid Systems

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and non-uniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kiris, Cetin↗
NASA NTRS2002

A Three-Dimensional Parallel Time-Accurate Turbopump Simulation Procedure Using Overset Grid System

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and nonuniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability are presented along with the performance of parallel versions of the code.

Kiris, Cetin↗
NASA NTRS2011

Small Scale Turbopump Manufacturing Technology and Material Processes

As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.

Alvarez, Erika↗
NASA NTRS1975

The dynamic performance of cavitating turbopumps

The evaluation of the transfer function for an axial cavitating inducer in a high performance turbopump is considered. An approach for the evaluation of the compliance and mass flow gain factor can be used as a basis for the determination of the first nonzero terms in the expansions of all the elements in the transfer function. Applications of the described method to turbopumps are discussed and the theoretical results are compared with test observations in the case of the Saturn J2 engine. It is demonstrated that a dynamic transfer function which includes not only a compliance but also a mass flow gain factor is a satisfactory first approximation for a cavitating turbopump.

Brennen, C.↗
NASA NTRS1977

Small, high-pressure liquid hydrogen turbopump

A high pressure, liquid hydrogen turbopump was designed, fabricated, and tested to a maximum speed of 9739 rad/s and a maximum pump discharge pressure of 2861 N/sq. cm. The approaches used in the analysis and design of the turbopump are described, and fabrication methods are discussed. Data obtained from gas generator tests, turbine performance calibration, and turbopump testing are presented.

Csomor, A.↗
NASA NTRS1977

Small, high-pressure liquid oxygen turbopump

A small, high-pressure, liquid oxygen turbopump was designed, fabricated, and tested. The pump was of a single-stage, centrifugal type; power to the pump was supplied by a single-stage, partial emission, axial-impulse turbine. Design conditions included an operating speed of 70,000 rpm, pump discharge pressure of 2977 N/sq cm (4318 psia), and a pump flowrate of 16.4 kg/s (36.21 lb/sec). The turbine was propelled by LO2/LH2 combustion products at 1041 K (1874 R) inlet temperature, and at a design pressure ratio of 1.424. The approaches used in the detail analysis and design of the turbopump are described, and fabrication methods are discussed. Data obtained from gas generator tests, turbine performance calibration, and turbopump testing are presented.

Csomor, A.↗
NASA NTRS1980

Evaluation of space shuttle main engine bearings from high pressure oxygen turbopump 9008

Two used turbopump mainshaft support bearings were examined to determine steps needed to achieve turbopump lifetimes of 27,000 seconds. The two bearings, which had been run in a high pressure oxygen turbopump, are angular contact ball bearings, applied as a preloaded pair, locked to the shaft, inner race rotating, with the outer races unrestrained axially. Examination showed that both bearings had been subjected to overloads, leading to fatigue spalling on the races and balls and advanced retainer wear. This is clear evidence of unintended high internal loads in the high pressure oxygen pump which would lead to complete bearing failure and extensive secondary pump damage. Action must be taken to reduce the applied bearing loads or to incorporate bearings of sufficient size to withstand the high loads.

Dufrane, K. F.↗
NASA NTRS1984

Rotordynamic Characteristics of the HPOTP (High Pressure Oxygen Turbopump) of the SSME (Space Shuttle Main Engine)

Rotational stability of turbopump components in the space shuttle main engine was studied via analysis of component and structural dynamic models. Subsynchronous vibration caused unacceptable migration of the rotor/housing unit with unequal load sharing of the synchronous bearings that resulted in the failure of the High Pressure Oxygen Turbopump. Linear analysis shows that a shrouded inducer eliminates the second critical speed and the stability problem, a stiffened rotor improves the rotordynamic characteristics of the turbopump, and installing damper boost/impeller seals reduces bearing loads. Nonlinear analysis shows that by increasing the "dead band' clearances, a marked reduction in peak bearing loads occurs.

Childs, D. W.↗
NASA NTRS1984

Measurements of elastohydrodynamic film thickness, wear and tempering behavior of high pressure oxygen turbopump bearings

The reusable design of the Space Shuttle requires a target life of 7.5 hours for the turbopumps of the Space Shuttle main engine (SSME). This large increase from the few hundred seconds required in single-use rockets has caused various problems with the bearings of the turbopumps. The berings of the high pressure oxygen turbopump (HPOTP) were of particular concern because of wear, spalling, and cage failures at service time well below the required 7.5 hours. Lubrication and wear data were developed for the bearings. Since the HPOTP bearings operate in liquid oxygen, conventional liquid lubricants cannot be applied. Therefore, solid lubricant coatings and lubricant transfer from the polytetrafluorethylene (FTFE) cage were the primary lubrication approaches for the bearings. Measurements were made using liquid nitrogen in a rolling disk machine to determine whether usable elastohydrodynamic films could be generated to assist in the bearing lubrication.

Dufrane, K. F.↗
NASA NTRS1984

Assessment of the operating characteristics of the SSME LOX turbopump pump-end bearing

A bearing/shaft model of the SSME LOX turbopump was developed using the SHABERTH bearing/shaft math modeling computer code. A previously developed bearing/shaft thermal model of the SSME LOX turbopump turbine and bearing was used in conjunction with SHABERTH to evaluate the thermomechanical operating characteristics of the LOX turbopump end bearings. Results show that for the two unmounted diametrical clearances evaluated (4.0 mils and 6.3 mils), the inboard pump end bearing supports about 81% of the isolator load for the small clearance and 77% of the isolator load for the larger clearance. Bearing clearance changes due to thermal effects were 40% for the 4.0 mil diametrical clearance case and 19% for the 6.3 mil clearance case evaluated. The thermal analysis included evaluation of bearing temperatures for a subcooled case and a saturated case. Results indicate that no drastic temperature change occurred between the two cases. Since the rolling element and race surfaces of the subcooled case were at temperatures sufficiently high enough to be vapor blanketed, exceeding saturation temperature at the bearing inlet did not increase surface temperatures greatly.

New, L. S.↗
NASA NTRS1984

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with reductions in maintenance costs and turn-around times can be achieved with an engine condition monitoring systems (CMS). The CMS provides health status of critical engine components, without disassembly, through monitoring with advanced sensors. Engine failure reports over 35 years were categorized into 20 different modes of failure. Rotor bearings and turbine blades were determined to be the most critical in limiting turbopump life. Measurement technologies were matched to each of the failure modes identified. Three were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiberoptic deflectometer (bearings), and the fiberoptic pyrometer (blades). Signal processing algorithms were evaluated for their ability to provide useful health data to maintenance personnel. Design modifications to the Space Shuttle Main Engine (SSME) high pressure turbopumps were developed to incorporate the sensors. Laboratory test fixtures have been designed for monitoring the rotor bearings and turbine blades in simulated turbopump operating conditions.

Hampson, M. E.↗
NASA NTRS1988

An expert system approach to turbopump health monitoring

A preliminary report is presented on the development of a system for monitoring the High Pressure Oxidizer Turbopump of the SSME. System development will proceed by defining the degradation mechanism of the turbopump, identifying those conventional and advanced sensor measurements that can monitor these mechanisms, and determining the digital processing requirements for these measurements. Once the failures and associated measurements have been defined, an expert system will be developed that can make both diagnostic and prognostic inferences about the condition and performance of the turbopump.

Perry, John G.↗
NASA NTRS1988

Cryogenic, high speed, turbopump bearing cooling requirements

Although the Space Shuttle Main Engine (SSME) has repeatedly demonstrated the capability to perform during launch, the High Pressure Oxidizer Turbopump (HPOTP) main shaft bearings have not met their 7.5 hour life requirement. A tester is being employed to provide the capability of subjecting full scale bearings and seals to speeds, loads, propellants, temperatures, and pressures which simulate engine operating conditions. The tester design permits much more elaborate instrumentation and diagnostics than could be accommodated in an SSME turbopump. Tests were made to demonstrate the facilities; and the devices' capabilities, to verify the instruments in its operating environment and to establish a performance baseline for the flight type SSME HPOTP Turbine Bearing design. Bearing performance data from tests are being utilized to generate: (1) a high speed, cryogenic turbopump bearing computer mechanical model, and (2) a much improved, very detailed thermal model to better understand bearing internal operating conditions. Parametric tests were also made to determine the effects of speed, axial loads, coolant flow rate, and surface finish degradation on bearing performance.

Dolan, Fred J.↗
NASA NTRS1990

Balancing low cost with reliable operation in the rotordynamic design of the ALS Liquid Hydrogen Fuel Turbopump

The Air Force/NASA Advanced Launch System (ALS) Liquid Hydrogen Fuel Turbopump (FTP) has primary design goals of low cost and high reliability, with performance and weight having less importance. This approach is atypical compared with other rocket engine turbopump design efforts, such as on the Space Shuttle Main Engine (SSME), which emphasized high performance and low weight. Similar to the SSME turbopumps, the ALS FTP operates supercritically, which implies that stability and bearing loads strongly influence the design. In addition, the use of low cost/high reliability features in the ALS FTP such as hydrostatic bearings, relaxed seal clearances, and unshrouded turbine blades also have a negative influence on rotordynamics. This paper discusses the analysis conducted to achieve a balance between low cost and acceptable rotordynamic behavior, to ensure that the ALS FTP will operate reliably without subsynchronous instabilities or excessive bearing loads.

Greenhill, L. M.↗
NASA NTRS1992

Three-dimensional turbopump flowfield analysis

A program was conducted to develop a flow prediction method applicable to rocket turbopumps. The complex nature of a flowfield in turbopumps is described and examples of flowfields are discussed to illustrate that physics based models and analytical calculation procedures based on computational fluid dynamics (CFD) are needed to develop reliable design procedures for turbopumps. A CFD code developed at NASA ARC was used as the base code. The turbulence model and boundary conditions in the base code were modified, respectively, to: (1) compute transitional flows and account for extra rates of strain, e.g., rotation; and (2) compute surface heat transfer coefficients and allow computation through multistage turbomachines. Benchmark quality data from two and three-dimensional cascades were used to verify the code. The predictive capabilities of the present CFD code were demonstrated by computing the flow through a radial impeller and a multistage axial flow turbine. Results of the program indicate that the present code operated in a two-dimensional mode is a cost effective alternative to full three-dimensional calculations, and that it permits realistic predictions of unsteady loadings and losses for multistage machines.

Sharma, O. P.↗
NASA NTRS1992

Cold flow testing of the Space Shuttle Main Engine alternate turbopump development high pressure fuel turbine model

NASA's Marshall Space Flight Center has established a cold airflow turbine test program to experimentally determine the performance of liquid rocket engine turbopump drive turbines. Testing of the SSME alternate turbopump development (ATD) fuel turbine was conducted for back-to-back comparisons with the baseline SSME fuel turbine results obtained in the first quarter of 1991. Turbine performance, Reynolds number effects, and turbine diagnostics, such as stage reactions and exit swirl angles, were investigated at the turbine design point and at off-design conditions. The test data showed that the ATD fuel turbine test article was approximately 1.4 percent higher in efficiency and flowed 5.3 percent more than the baseline fuel turbine test article. This paper describes the method and results used to validate the ATD fuel turbine aerodynamic design. The results are being used to determine the ATD high pressure fuel turbopump (HPFTP) turbine performance over its operating range, anchor the SSME ATD steady-state performance model, and validate various prediction and design analyses.

Gaddis, Stephen W.↗