Performance and load-range characteristics of turbojet engine in transonic speed range
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COMPRESSORS - PRESSURE RATIO↗
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Aerodynamic and Aeroacoustic Wind Tunnel Testing of the Orion Spacecraft
The Orion aerodynamic testing team has completed more than 40 tests as part of developing the aerodynamic and loads databases for the vehicle. These databases are key to achieving good mechanical design for the vehicle and to ensure controllable flight during all potential atmospheric phases of a mission, including launch aborts. A wide variety of wind tunnels have been used by the team to document not only the aerodynamics but the aeroacoustic environment that the Orion might experience both during nominal ascents and launch aborts. During potential abort scenarios the effects of the various rocket motor plumes on the vehicle must be accurately understood. The Abort Motor (AM) is a high-thrust, short duration motor that rapidly separates Orion from its launch vehicle. The Attitude Control Motor (ACM), located in the nose of the Orion Launch Abort Vehicle, is used for control during a potential abort. The 8 plumes from the ACM interact in a nonlinear manner with the four AM plumes which required a carefully controlled test to define the interactions and their effect on the control authority provided by the ACM. Techniques for measuring dynamic stability and for simulating rocket plume aerodynamics and acoustics were improved or developed in the course of building the aerodynamic and loads databases for Orion.
Ross, James C.↗
Gripper Test Assembly Status of Fabrication and Assembly Report – FY2023
The Gripper Test Assembly (GrTA) is an experimental test article designed for use at the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GrTA will test mechanical components intended for use in compact in-vessel fuel handling machines (FHM) for sodium cooled fast reactors (SFR). The GrTA will test radial and thrust ball bearings, radial and thrust roller bearings, ball screws and nuts, spline shafts and ball nuts, radial spur gears, and universal joints submerged in liquid sodium at high temperatures (250°C-650°C). These components will be tested in a prototypic, full-scale gripper head and under prototypic SFR fuel handling loads. The design of the GrTA was completed in FY2022 and has progressed into fabrication and initial assembly. All custom manufactured components have been fabricated and delivered to ANL following inspection. All custom gears have been fabricated and delivered to ANL. Bearings, ball screws, and spline shafts have been purchased to allow for initial assembly in air, and sodium compatible versions have either been purchased or are in design at appropriate manufacturers. The drive motor systems that operate the various functions of the GrTA have been purchased and delivered to ANL. Instrumentation and control hardware has been purchased and delivered to ANL as well. All sodium facing components of the GrTA have been assembled and show proper fit. The three main functions of the GrTA are to raise or lower a gripper head under prototypic fuel handling loads, rotate the gripper head while carrying a fuel handling load, and extend or retract gripper jaws that lock a fuel assembly to the gripper head. All three functions have been demonstrated in air, while under no load. The GrTA project will move forward next fiscal year by completing the initial assembly, incorporating the drive system and I&C, and preparing the assembly for introduction to sodium.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Quick look test report: MPT static firing no. 2 test MPT-S2
The three engine cluster was fired at 70 percent power level for a nominal 15 seconds to evaluate the integrated performance of the main propulsion system. Engine ignition occurred at approximately 1403 with the planned mainstage duration achieved for all three engines. Operation of all systems was as expected with the exception of the recirculation pumps. The pumps were started while the propellant loading was in fast fill, but they cavitated and lost head at the termination of fast fill. The pumps were subsequently restarted after pressurizing the tank and draining back propellant to get good quality. Post test inspection of the engines revealed some discoloration on the inside of the thrust chamber and distorted drain lines for engine #2.
Source record↗
An Updated Assessment of NASA Ultra-Efficient Engine Technologies
NASA's Ultra Efficient Engine Technology (UEET) project features advanced aeropropulsion technologies that include highly loaded turbomachinery, an advanced low-NOx combustor, high-temperature materials, and advanced fan containment technology. A probabilistic system assessment is performed to evaluate the impact of these technologies on aircraft CO2 (or equivalent fuel burn) and NOx reductions. A 300-passenger aircraft, with two 396-kN thrust (85,000-lb) engines is chosen for the study. The results show that a large subsonic aircraft equipped with the current UEET technology portfolio has very high probabilities of meeting the UEET minimum success criteria for CO2 reduction (-12% from the baseline) and LTO (landing and takeoff) NOx reductions (-65% relative to the 1996 International Civil Aviation Organization rule).
Tong Michael T.↗
The Grid Density Dependence of the Unsteady Pressures of the J-2X Turbines
The J-2X engine was originally designed for the upper stage of the cancelled Crew Launch Vehicle. Although the Crew Launch Vehicle was cancelled the J-2X engine, which is currently undergoing hot-fire testing, may be used on future programs. The J-2X engine is a direct descendent of the J-2 engine which powered the upper stage during the Apollo program. Many changes including a thrust increase from 230K to 294K lbf have been implemented in this engine. As part of the design requirements, the turbine blades must meet minimum high cycle fatigue factors of safety for various vibrational modes that have resonant frequencies in the engine's operating range. The unsteady blade loading is calculated directly from CFD simulations. A grid density study was performed to understand the sensitivity of the spatial loading and the magnitude of the on blade loading due to changes in grid density. Given that the unsteady blade loading has a first order effect on the high cycle fatigue factors of safety, it is important to understand the level of convergence when applying the unsteady loads. The convergence of the unsteady pressures of several grid densities will be presented for various frequencies in the engine's operating range.
Schmauch, Preston B.↗
Lightweight Thrust Chamber Composite Overwrap Lessons Learned
Filament winding a polymer/carbon fiber composite overwrap onto an additively manufactured copper combustion chamber will allow it to act as a light-weight structural jacket, significantly reducing weight for high pressure thrust chamber assemblies and reducing overall cost and fabrication schedules. Chamber assemblies for 2k lb. and 7k lb. of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. The recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.
composite overwrap↗
Arcjet load characteristics
Experiments were conducted to define the interface characteristics and constraints of 1 kW class arcjets run on simulated decomposition products of hydrazine and power processors. The impacts of power supply output current ripple on arcjet performance were assessed by variation of the ripple frequency from 100 Hz to 100 kHz with 10 percent peak-to-peak ripple amplitude at 1.2 kW. Ripple had no significant effects on thrust, specific impulse or efficiency. The impact of output ripple on thruster lifetime was not assessed. The static and dynamic impedances of the arcjet were quantified with two thrusters of nearly identical configuration. Superposition of an AC component on the DC arc current was used to characterize the dynamic impedance as a function of flow rate and DC current level. A mathematical model was formulated from these data. Both the static and dynamic impedance magnitude were found to be dependent on mass flow rate. The amplitude of the AC component was found to have little effect on the dynamic impedance. Reducing the DC level from 10 to 8 amps led to a large change in the magnitude of the dynamic impedance with no observable phase change. The impedance data compared favorably between the two thrusters.
Hamley, John A.↗
Arcjet load characteristics
Experiments were conducted to define the interface characteristics and constraints of 1 kW class arcjets run on simulated decomposition products of hydrazine and power processors. The impacts of power supply output current ripple on arcjet performance were assessed by variation of the ripple frequency from 100 Hz to 100 kHz with 10 percent peak-to-peak ripple amplitude at 1.2 kW. Ripple had no significant effects on thrust, specific impulse or efficiency. The impact of output ripple on thruster lifetime was not assessed. The static and dynamic impedances of the arcjet were quantitied with two thrusters of nearly identical configuration. Superposition of an AC component on the DC arc current was used to characterize the dynamic impedance as a function of flow rate and DC current level. A mathematical model was formulated from these data. Both the static and dynamic impedance magnitude were found to be dependent on mass flow rate. The amplitude of the AC component was found to have little effect on the dynamic impedance. Reducing the DC level from 10 to 8 amps led to a large change in the magnitude of the dynamic impedance with no observable phase change. The impedance data compared favorably between the two thrusters.
Hamley, John A.↗
Applications of higher harmonic control to hingeless rotor systems
A comprehensive analytical formulation was developed to predict the vibratory hub loads of a helicopter rotor system in forward flight. This analysis is used to calculate the optimal higher harmonic control inputs and associated actuator power required to minimize these hub loads. The present formulation is based on a finite element method in space and time. A nonlinear time domain, unsteady aerodynamic model is used to obtain the airloads, and the rotor induced inflow is calculated using a nonuniform inflow model. Predicted vibratory hub loads are correlated with experimental data from a scale model rotor. Results of a parametric study on a hindgeless rotor show that blade flap, lag and torsion vibration characteristics, offset of blade center of mass from elastic axis, offset of elastic axis from quarter-chord axis, and blade thrust greatly affect the higher harmonic control actuator power requirement.
Nguyen, Khanh↗
Rover/NERVA-derived near-term nuclear propulsion
FY-92 accomplishments centered on conceptual design and analyses for 25, 50, and 75 K engines with emphasis on the 50 K engine. During the first period of performance, flow and energy balances were prepared for each of these configurations and thrust-to-weight values were estimated. A review of fuel technology and key data from the Rover/NERVA program established a baseline for proven reactor performance and areas of enhancement to meet near-term goals. Studies were performed of the criticality and temperature profiles for probable fuel and moderator loadings for the three engine sizes, with a more detailed analysis of the 50 K size. During the second period of performance, analyses of the 50 K engine continued. A chamber/nozzle contour was selected and heat transfer and fatigue analyses were performed for likely construction materials. Reactor analyses were performed to determine component radiation heating rates, reactor radiation fields, water immersion poisoning requirements, temperature limits for restartability, and a tie-tube thermal analysis. Finally, a brief assessment of key enabling technologies was made, with a view toward identifying development issues and identification of the critical path toward achieving engine qualification within 10 years.
Source record↗
A Change of Inertia-Supporting the Thrust Vector Control of the Space Launch System
The Space Launch System (SLS) is America's next launch vehicle. To utilize the vehicle more economically, heritage hardware from the Space Transportation System (STS) will be used when possible. The Solid Rocket Booster (SRB) actuators could possibly be used in the core stage of the SLS. The dynamic characteristics of the SRB actuator will need to be tested on an Inertia Load Stand (ILS) that has been converted to Space Shuttle Main Engine (SSME). The inertia on the pendulum of the ILS will need to be changed to match the SSME inertia. In this testing environment an SRB actuator can be tested with the equivalent resistence of an SSME.
Dziubanek, Adam J.↗
Conducting Wall Hall Thrusters
A unique configuration of the magnetic field near the wall of Hall thrusters, called Magnetic Shielding, has recently demonstrated the ability to significantly reduce the erosion of the boron nitride (BN) walls and extend the life of Hall thrusters by orders of magnitude. The ability of magnetic shielding to minimize interactions between the plasma and the discharge chamber walls has for the first time enabled the replacement of insulating walls with conducting materials without loss in thruster performance. The boron nitride rings in the 6 kW H6 Hall thruster were replaced with graphite that self-biased to near the anode potential. The thruster efficiency remained over 60% (within two percent of the baseline BN configuration) with a small decrease in thrust and increase in Isp typical of magnetically shielded Hall thrusters. The graphite wall temperatures decreased significantly compared to both shielded and unshielded BN configurations, leading to the potential for higher power operation. Eliminating ceramic walls makes it simpler and less expensive to fabricate a thruster to survive launch loads, and the graphite discharge chamber radiates more efficiently which increases the power capability of the thruster compared to conventional Hall thruster designs.
electric propulsion (EP)↗
Application of higher harmonic control to hingeless rotor systems
A comprehensive analytical formulation has been dveloped to predict the vibratory hub loads of a helicopter rotor system in forward flight. The analysis is used to calculate the optimal higher harmonic control inputs and associated actuator power required to minimize these hub loads. The present formulation is based on a finite element method in space and time. A nonlinear time domain, unsteady aerodynamic model is used to obtain the airloads, and the rotor induced inflow is calculated using a nonuniform inflow model. Predicted vibratory hub loads are correlated with experimental data obtained from a scaled model rotor. Results of a parametric study on a hingeless rotor show that blade flap, lag and torsion vibration characteristics, offset of blade center of mass from elastic axis, offset of elastic axis from quarter-chord axis, and blade thrust greatly affect the higher harmonic control actuator power requirement.
Nguyen, Khanh↗
Design of a Propeller with Global Minimum Torque
Academia, industry, and Government are actively working towards a future where dozens of small to large Unmanned Aerial Systems (UAS) are present within urban environments. In this environment, high noise pollution and inefficiencies have the potential to render these new technologies impractical due to public annoyance and nonacceptance. This study aims to design and analyze a novel propeller design for minimum global torque using an optimization algorithm to find the full three dimensional solution of maximum efficiency. This resulted in a 𝐶 𝑙 distribution defining the global minimum torque solution for propeller design which corresponded with moving as much lift inboard as possible and reducing lift rapidly at the blade tip. The novel propeller (dubbed "Prandtl" propeller) was then compared with the current gold standard in propeller design, a minimum induced loss (MIL) propeller, which had all the same geometric properties except for blade twist and produced the same amount of thrust at the same advance ratio. The results of multiple iterations of Prandtl propellers showed an increase in efficiency of 2.0-3.3% for the Prandtl blade when compared to the equivalent MIL blade. A potential added benefit of this blade design is lower noise generation due to the lower lift loading at the tip reducing the large shear layer intensity which is the point source of noise in propellers. Two major breakthroughs for enabling widespread use of UAS in urban environments are noise reduction and vehicle efficiency, and this new propeller design has the potential to provide both.
Propeller↗
Design of a Propeller with Global Minimum Torque
Academia, industry, and Government are actively working towards a future where dozens of small to large Unmanned Aerial Systems (UAS) are present within urban environments. In this environment, high noise pollution and inefficiencies have the potential to render these new technologies impractical due to public annoyance and nonacceptance. This study aims to design and analyze a novel propeller design for minimum global torque using an optimization algorithm to find the full three dimensional solution of maximum efficiency. This resulted in a 𝐶 𝑙 distribution defining the global minimum torque solution for propeller design which corresponded with moving as much lift inboard as possible and reducing lift rapidly at the blade tip. The novel propeller (dubbed "Prandtl" propeller) was then compared with the current gold standard in propeller design, a minimum induced loss (MIL) propeller, which had all the same geometric properties except for blade twist and produced the same amount of thrust at the same advance ratio. The results of multiple iterations of Prandtl propellers showed an increase in efficiency of 2.0-3.3% for the Prandtl blade when compared to the equivalent MIL blade. A potential added benefit of this blade design is lower noise generation due to the lower lift loading at the tip reducing the large shear layer intensity which is the point source of noise in propellers. Two major breakthroughs for enabling widespread use of UAS in urban environments are noise reduction and vehicle efficiency, and this new propeller design has the potential to provide both.
Propeller↗
Technology development and demonstration of a low thrust resistojet thruster
Three thrusters were fabricated to definitized thruster drawings using new rhenium vapor deposition technology. Two of the thrusters were operated using ammonia as propellant and one was operated using hydrogen propellant for performance determination. All demonstrated consistent operational specific impulse performance while demonstrating thermal performance better than the development units from which they evolved. Two of the thrusters were subjected to environmental structural testing including vibration, acceleration and shock loading to specifications. Both of the thrusters subjected to the environmental tests passed all required tests. The third, spare, thruster was introduced into the life test portion of the program. Two thrusters were then subjected to a life cycling test program under typical spacecraft operating power levels. During the life test sequence, the hydrogen thruster accrued 720 operating life test cycles, more than 370 on-off cycles and 365 hours of powered up time. The ammonia accrued approximately 380 on-off cycles and 392.2 on time hours of operation during the 720 cycling hour test. Both thrusters completed the scheduled operational life test in reasonably good condition, structurally integral and capable of indefinite further operation.
Pfeifer, G. R.↗
The theory of propellers IV : thrust, energy, and efficiency formulas for single and dual rotating propellers with ideal circulation distribution
Simple and exact expressions are given for the efficiency of single and dual rotating propellers with ideal circulation distribution as given by the Goldstein functions for single-rotating propellers and by the new functions for dual-rotating propellers from part I of the present series. The efficiency is shown to depend primarily on a defined load factor and, to a very small extent, on an axial loss factor. Tables and charts are included for practical use of the results.
Theodorsen, Theodore↗