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At least 613 records · Page 34

Analytical and experimental studies of heat pipe radiation cooling of hypersonic propulsion systems

Analytical and experimental studies were completed to assess the feasibility of using high-temperature heat pipes to cool hypersonic engine components. This new approach involves using heat pipes to transport heat away from the combustor, nozzle, or inlet regions, and to reject it to the environment by thermal radiation from an external heat pipe nacelle. For propulsion systems using heat pipe radiation cooling (HPRC), it is possible to continue to use hydrocarbon fuels into the Mach 4 to Mach 6 speed range, thereby enhancing the economic attractiveness of commercial or military hypersonic flight. In the second-phase feasibility program recently completed, it is found that heat loads produced by considering both convection and radiation heat transfer from the combustion gas can be handled with HPRC design modifications. The application of thermal insulation to ramburner and nozzle walls was also found to reduce the heat load by about one-half and to reduce peak HPRC system temperatures to below 2700 F. In addition, the operation of HPRC at cruise conditions of around Mach 4.5 and at an altitude of 90,000 ft lowers the peak hot-section temperatures to around 2800 F. An HPRC heat pipe was successfully fabricated and tested at Mach 5 conditions of heat flux, heat load, and temperature.

Martin, R. A.↗

Comparative analysis of characteristics of a supersonic cw chemical HF laser on molecular fluorine and nitrogen trifluoride

We have experimentally studied the characteristics of a supersonic cw chemical HF laser with a flat nozzle array based on a nozzle – nozzle reagent mixing scheme operating with the use of F{sub 2} – D{sub 2} – He and NF{sub 3} – D{sub 2} – He fuel compositions in an atomic fluorine generator. The active medium flow field pattern, its gas-dynamic characteristics, and the laser radiation spectrum are considered. The comparison of these characteristics has made it possible to establish a strong impact on the flow field (lasing zone length) of the chemical composition of the combustion products from the atomic fluorine generator. The gas-dynamic parameters of the active medium formed by using a NF{sub 3} – D{sub 2} – He fuel have turned out to be less acceptable in terms of the gas flow pressure recovery than in the case of F{sub 2} – D{sub 2} – He fuel, while the radiation spectrum was more preferable from the viewpoint of passing through the atmosphere. (paper)

36 MATERIALS SCIENCE↗

Assessment of Heavy-Duty Fueling Methods and Components

Chevron, NLR, ANL, and NextEnergy partnered in the development of a comprehensive assessment of heavy-duty (HD) fuel cell electric vehicle fueling protocols. The project leveraged and built upon existing international heavy-duty (HD) fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, techno-economic assessments of industry-selected protocol structures and experimental validations of the strategies performed at NLR's HD hydrogen fueling station.

08 HYDROGEN↗

Experimental investigation of combustor effects on rocket thrust chamber performance

The results are reported of a program to develop special instrumentation systems and engine hardware, conduct tests using LOX/GH2 propellants wherein radial mixtures ratio stratification was controlled, and subsequently compare the results of four selected tests with the predictions of the JANNAF performance-prediction computer programs. During the experiments, the overall propellant mixture ratio was varied from 4.4 to 6.6, while the mixture ratios in the core and outer zone were varied from 5.7 to 8.8 and from 3.7 to 7.2, respectively. A nominal 10 percent of the total fuel flow was used as boundary layer collant in a majority of the firings. Nominal chamber pressure was either 225 or 250 psia, with nozzle expansion ratios of either 25:1 or 4:1. Measurements of the axial chamber pressure and wall heat flux profiles, together with samples of the exhaust gas, were obtained. The corrected experimental specific impulse and characteristic exhaust velocity efficiencies were approximately 97.5 and 98.5 percent, respectively.

Nurick, W. H.↗

Vacuum plasma spray applications on liquid fuel rocket engines

The vacuum plasma spray process (VPS) has been developed by NASA and Rocketdyne for a variety of applications on liquid fuel rocket engines, including the Space Shuttle Main Engine. These applications encompass thermal barrier coatings which are thermal shock resistant for turbopump blades and nozzles; bond coatings for cryogenic titanium components; wear resistant coatings and materials; high conductivity copper, NaRloy-Z, combustion chamber liners, and structural nickel base material, Inconel 718, for nozzle and combustion chamber support jackets.

Mckechnie, T. N.↗

Numerical analyses of a rocket engine turbine and comparison with air test data

The study presents cold air test data on the Space Shuttle Main Engine High Pressure Fuel Turbopump turbine recently collected at the NASA Marshall Space Flight Center. Overall performance data, static pressures on the first- and second-stage nozzles, and static pressures along with the gas path at the hub and tip are gathered and compared with various (1D, quasi-3D, and 3D viscous) analysis procedures. The results of each level of analysis are compared to test data to demonstrate the range of applicability for each step in the design process of a turbine. One-dimensional performance prediction, quasi-3D loading prediction, 3D wall pressure distribution prediction, and 3D viscous wall pressure distribution prediction are illustrated.

Tran, Ken↗

Flow and Heat Transfer in 180-Degree Turn Square Ducts: Effects of Turning Configuration and System Rotation

Forced flow through channels connected by sharp bends is frequently encountered in various rocket and gas turbine engines. For example, the transfer ducts, the coolant channels surround the combustion chamber, the internal cooling passage in a blade or vane, the flow path in the fuel element of a nuclear rocket engine, the flow around a pressure relieve valve piston, and the recirculated base flow of multiple engine clustered nozzles. Transport phenomena involved in such a flow passage are complex and considered to be very different from those of conventional turning flow with relatively mild radii of curvature. While previous research pertaining to this subject has been focused primarily on the experimental heat transfer, very little analytical work is directed to understanding the flowfield and energy transport in the passage. Therefore, the primary goal of this paper is to benchmark the predicted wall heat fluxes using a state-of-the-art computational fluid dynamics (CFD) formulation against those of measurement for a rectangular turn duct. Other secondary goals include studying the effects of turning configurations, e.g., the semi-circular turn, and the rounded-corner turn, and the effect of system rotation. The computed heat fluxes for the rectangular turn duct compared favorably with those of the experimental data. The results show that the flow pattern, pressure drop, and heat transfer characteristics are different among the three turning configurations, and are substantially different with system rotation. Also demonstrated in this work is that the present computational approach is quite effective and efficient and will be suitable for flow and thermal modeling in rocket and turbine engine applications.

Wang, Ten-See↗

Discharge characteristics of a double injection-valve single-pump injection system

The discharge characteristics of two similar injection valves operated by a single-cylinder fuel-injection pump were determined with an apparatus that measured the quantity of fuel discharged from each valve during every 0.5 degrees of pump rotation. It was found that similar discharges took place from the two valves at all pump speeds when the valve-opening pressures, the nozzle-orifice diameters, and the injection-tube lengths were the same for both valves. Under these conditions, the effects of changing the pump speed, the pump throttle setting, or the nozzle orifice diameter were very similar to those occurring with a single-injection valve. By a proper selection of discharge-orifice areas and valve-opening pressures it was possible to obtain a great many combinations of discharge quantities, discharge rates, and injection timings for the two valves. A series of tests using injection tubes of unequal lengths for the two valves showed that under these conditions the injection timing and the fuel quantity discharged from each valve varies widely and erratically with changes in the pump speed.

Lee, Dana W↗

Conical diffuser for fuel cells

Diffuser is inserted into inlet manifold, producing smooth transition of flow from pipe diameter to manifold diameter. Expected pressure gradient and resulting cell-to-cell temperature gradient are reduced. Outlet manifold has nozzle insert that reduces exit losses.

Craft, D. W.↗

Experimental Comparison of Hydrogen Refueling with Directly Pressurized vs. Cascade Method

This paper presents a comparative analysis of two hydrogen station configurations during the refueling process: the conventional “directly pressurized refueling process” and the innovative “cascade refueling process.” The objective of the cascade process is to refuel vehicles without the need for booster compressors. The experiments were conducted at the Hydrogen Research and Fueling Facility located at California State University, Los Angeles. In the cascade refueling process, the facility buffer tanks were utilized as high-pressure storage, enabling the refueling operation. Three different scenarios were tested: one involving the cascade refueling process and two involving compressor-driven refueling processes. On average, each refueling event delivered 1.6 kg of hydrogen. Although the cascade refueling process using the high-pressure buffer tanks did not achieve the pressure target, it resulted in a notable improvement in the nozzle outlet temperature trend, reducing it by approximately 8 °C. Moreover, the overall hydrogen chiller load for the two directly pressurized refuelings was 66 Wh/kg and 62 Wh/kg, respectively, whereas the cascading process only required 55 Wh/kg. This represents a 20% and 12% reduction in energy consumption compared to the scenarios involving booster compressors during fueling. The observed refueling range of 150–350 bar showed that the cascade process consistently required 12–20% less energy for hydrogen chilling. Additionally, the nozzle outlet temperature demonstrated an approximate 8 °C improvement within this pressure range. These findings indicate that further improvements can be expected in the high-pressure region, specifically above 350 bar. This research suggests the potential for significant improvements in the high-pressure range, emphasizing the viability of the cascade refueling process as a promising alternative to the direct compression approach.

08 HYDROGEN↗

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗

An experimental investigation of a supersonic vortical flow

Although much research has been done on subsonic vortical flow, the current understanding of these flows remains limited. The effect is characterized of adding swirl to a supersonic jet. The motive is to study the enhancement of supersonic mixing in order to provide more efficient fuel injectors for supersonic combustion (scramjet) engines. The vortical flow was created by tangential injection into a swirl chamber ahead of a converging and/or diverging nozzle. The amount of swirl was varied by changing the number of tangential injection holes and with the removal of the end piece, the jet could be run without swirl. Shadowgraphy, conventional schlieren, and focusing schlieren were used to obtain a qualitative understanding of the jet flow structure. It was determined that an increase in swirl produced an increase in the shear layer growth. Pressure and temperature probes were used to obtain more flow data. The probe data compared favorably with the theoretical calculations, except in the viscous core where viscous effects were not considered negligible. These results verified that a supersonic vortical flow was being created with a maximum helix angle of 33 degs.

Levey, Brian S.↗

Propagation of a Free Flame in a Turbulent Gas Stream

Effective flame speeds of free turbulent flames were measured by photographic, ionization-gap, and photomultiplier-tube methods, and were found to have a statistical distribution attributed to the nature of the turbulent field. The effective turbulent flame speeds for the free flame were less than those previously measured for flames stabilized on nozzle burners, Bunsen burners, and bluff bodies. The statistical spread of the effective turbulent flame speeds was markedly wider in the lean and rich fuel-air-ratio regions, which might be attributed to the greater sensitivity of laminar flame speed to flame temperature in those regions. Values calculated from the turbulent free-flame-speed analysis proposed by Tucker apparently form upper limits for the statistical spread of free-flame-speed data. Hot-wire anemometer measurements of the longitudinal velocity fluctuation intensity and longitudinal correlation coefficient were made and were employed in the comparison of data and in the theoretical calculation of turbulent flame speed.

Mickelsen, William R↗

Theoretical Performance of Hydrogen-Oxygen Rocket Thrust Chambers

Data are presented for liquid-hydrogen-liquid-oxygen thrust chambers at chamber pressures from 15 to 1200 pounds per square inch absolute, area ratios to approximately 300, and percent fuel from about 8 to 34 for both equilibrium and frozen composition during expansion. Specific impulse in vacuum, specific impulse, combustion-chamber temperature, nozzle-exit temperature, characteristic velocity, and the ratio of chamber-to-nozzle-exit pressure are included. The data are presented in convenient graphical forms to allow quick calculation of theoretical nozzle performance with over- or underexpansion, flow separation, and introduction of the propellants at various initial conditions or heat loss from the combustion chamber.

Sievers, Gilbert K.↗

Base Flow Characteristics for Several Four-Clustered Rocket Configurations at Mach Numbers from 2.0 to 3.5

A generalized study of base flow phenomena has been conducted with four 500-pound-thrust JP-4 fuel-liquid-oxygen rocket motors installed in the base of a 12-inch-diameter cylindrical model. Data were obtained over a Mach number and nozzle pressure ratio range of 2.0 to 3.5 and 340 to 600, respectively. Base heat flux, gas temperature, and pressure were highest in the center of the cluster core and decreased in a radial direction. Although a maximum heat flux of 93 Btu per square foot per second was measured within the cluster core, peripheral heat fluxes were low, averaging about 5 Btu per square foot per second for all configurations. Generally base heat flux was found to be independent of Mach number over the range investigated. Base heat flux within the cluster core was decreased by increasing motor spacing, motor extension, a combination of increasing nozzle area ratio and decreasing exit angle and gimbaling the two side engines. Small amounts of nitrogen injected within the cluster core sharply reduced core heat flux.

Musial, Norman T.↗

Atlas SOHO Booster and Centaur Erection

The launch vehicle for the Solar Heliospheric Observatory (SOHO) mission is a two stage Atlas-IIAS (Atlas/Centaur). The Atlas, consists of a solid rocket booster stage powered by four Thiokol Castor IVA solid rocket boosters (SRB) and a core vehicle stage (booster and sustainer) powered by Rocketdyne MA-5A liquid propellant engines (RP-1 fuel and liquid oxygen). The multiple firing Centaur is powered by two Pratt and Whitney (RL10A-4) liquid hydrogen and liquid oxygen engines with extendible nozzles. This video shows the erection of the Atlas booster and transportation (to 36-B launching pad) and erection of the Centaur.

Source record↗

Restoring Redundancy to the MAP Propulsion System

The Microwave Anisotropy Probe is a follow-on to the Differential Microwave Radiometer instrument on the Cosmic Background Explorer. Sixteen months before launch, it was discovered that from the time of the critical design review, configuration changes had resulted in a significant migration of the spacecraft's center of mass. As a result, the spacecraft no longer had a viable backup control mode in the event of a failure of the negative pitch axis thruster. Potential solutions to this problem were identified, such as adding thruster plume shields to redirect thruster torque, adding mass to, or removing it from, the spacecraft, adding an additional thruster, moving thrusters, bending thrusters (either nozzles or propellant tubing), or accepting the loss of redundancy for the thruster. The impacts of each solution, including effects on the mass, cost, and fuel budgets, as well as schedule, were considered, and it was decided to bend the thruster propellant tubing of the two roll control thrusters, allowing that pair to be used for back-up control in the negative pitch axis. This paper discusses the problem and the potential solutions, and documents the hardware and software changes that needed to be made to implement the chosen solution. Flight data is presented to show the propulsion system on-orbit performance.

ODonnell, James R., Jr.↗

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.↗