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State of the art and design criteria for liquid rocket engine turbopump inducers are summarized for optimal fabrication. Design criteria optimize hydrodynamic parameters to obtain highest suction specific speed without violating structural and mechanical constraints.
Consideration of the problem of reducing the probability of mechanical failure of bladder systems used for the expulsion of propellants into liquid rocket engines. It is shown that individual local folds in collapsing bladders can be classified into single and double folds, specifiable by nondimensional geometrical parameters which directly define the maximum strains at these folds. From these maximum strains the number of collapse/inflation cycles to failure can be obtained from low-cycle fatigue data experimentally determined for the bladder material of interest. Cycle life data are presented in terms of true maximum strain for four metals, two plastics, and two elastomers. It is found that double folds give rise to much more severe folding strains than do simple folds.
Brief accounts of the theoretical research conducted on the unsteady cavitation characteristics of liquid rocket engine turbopumps are reported. The objective is to produce estimates of the cavitation compliance and other unsteady characteristics which could then be used in analysis of the pogo instability. Blade cavitation is the particular pheonomenon which is investigated and line arized free streamline methods were employed in both quasistatic and complete dynamic cascade analyses of the unsteady flow. The simpler quasistatic analysis was applied to particular turbopumps but yielded values of compliances significantly smaller than those indirectly obtained from experiments. Reasons for this discrepancy are discussed. The complete dynamic analysis presents a new problem in fundamental hydrodynamics and, though the basic solution is presented, numerical results have not as yet been obtained.
Study of the dynamic response of streams of cavitating bubbles to imposed pressure fluctuations to determine the role played by turbopump cavitation in the POGO instability of liquid rockets. Both quasi-static and more general linearized dynamic analyses are made of the perturbations to a cavitating flow through a region of reduced pressure in which the bubbles first grow and then collapse. The results, when coupled with typical bubble number density distribution functions, yield compliances which compare favorably with the existing measurements. Since the fluids involved are frequently cryogenic, a careful examination was made of the thermal effects both on the mean flow and on the perturbations. As a result, the discrepancy between theory and experiment for particular engines could be qualitatively ascribed to reductions in the compliance caused either by these thermal effects or by relatively high reduced frequencies.
Monograph treats valve design technology problems as they were solved in successful development of flightweight operational valves for liquid rocket systems. General practices for cleaning and contamination prevention are summarized. Balance of information is arranged by topic, since detail design requirements apply to most types of valves.
Analysis and design of an optimum LO2/LH2, combustion topping cycle, 88,964 Newtons (20,000-pound) thrust, liquid rocket engine was conducted. The design selected is well suited to high-energy, upper-stage engine applications such as the Space Tug and embodies features directed toward optimization of vehicle performance. A configuration selection was conducted based on prior Air Force Contracts, and additional criteria for optimum stage performance. Following configuration selection, analyses and design of the major components and engine systems were conducted to sufficient depth to provide layout drawings suitable for subsequent detailing. In addition, engine packaging to a common interface and a retractable nozzle concept were defined. Alternative development plans and related costs were also established. The design embodies high-performance, low-weight, low NPSH requirements (saturated propellant inlet conditions at start), idle-mode operation, and autogenous pressurization. The design is the result of the significant past and current LO2/LH2 technology efforts of the NASA centers and the Air Force, as well as company-funded programs.
A new space transportation concept which is consistent with the need for more cost effective space operations has been developed. The major element of the Space Transportation System (STS) is the Space Shuttle. The rest of the system consists of a propulsive stage which can be carried within the space shuttle to obtain higher energy orbits. The final form of this propulsion stage will be called the Space Tug. A third important element, which is not actually a part of the STS since it has no propulsive capacity, is the Space Laboratory. The major element of the Space Shuttle is an aircraft-like orbiter which contains the crew, the cargo, and the liquid rocket engines in the rear.
Summary of a detailed engineering study conducted to evaluate the potential of composite engines when applied to the first stage of a two-stage manned advanced reusable launch vehicle. A total of 36 composite engines were evaluated for this mission/application. In all cases considered, composite engines were clearly shown to be superior when compared to an advanced liquid rocket engine. Payload in orbit results are presented for the more attractive composite engines. In addition, vehicle payload performance as a function of vehicle staging velocity is presented. Typical staging velocities are Mach 8 to 10.
Unsteady flow in a cavitating axial inducer pump is analyzed with the help of a simple two-dimensional cascade model. This problem was motivated by a desire to study the effect of unsteady cavitation on the so-called POGO instability in the operation of liquid rocket engines. Here, an important feature is a closed loop coupling between several different modes of oscillation, one of which is due to the basic unsteady characteristics of the cavitation itself. The approaching and leaving flow velocities up- and downstream of the inducer oscillate, and the cavity-blade system participates dynamically with the basic pulsating flow. In the present work, attention is focused on finding a transfer matrix that relates the set of upstream variables to those downstream. This quantity, which is essentially equivalent to cavitation compliance in the quasi-static analyses, is found to be complex and frequency dependent.
Rocketdyne, under contract to NASA-Lewis Research Center, is engaged in developing the technology for major subsystems of a small, high-performance, liquid rocket engine with the capabilities required for high-energy, upper-stage applications. Included in these efforts are the high-pressure turbopumps, preburner, igniter components, and high-area-ratio thrust chamber. A brief description of the engine system and its subsystems is given. The status of the programs is reviewed and the results of the testing conducted are presented.
An experimental LOX heat-transfer study and a LOX-cooled thrust-chamber demonstration program are summarized. Heat transfer to supercritical oxygen was investigated at 17 to 34.5 MPa (2460 to 5000 psia), and heat fluxes up to 90 MW/sq m (55 Btu/sq in.-sec). Experimental data obtained previously were correlated along with these recent data, and a design equation was derived which correlates 95% of the data within + or - 30%. Liquid-oxygen-cooled thrust chambers have been designed using this correlation and are currently being fabricated. A test program is planned for evaluating the LOX-cooled design concept using NASA test facilities. The purpose of these tests is to verify the LOX cooling correlation in a high-pressure liquid rocket engine and to determine the effects of a LOX coolant leak.
Expendable launch vehicles will be phased out during the first years of shuttle operation and the payloads currently carried to orbit by these vehicles will be placed in low earth orbit by the reusable shuttle. In connection with limitations regarding the weight of the payload which can be launched by the Space Shuttle in its present form, approaches have been considered for increasing the payload capability of the Shuttle. Propulsion systems for Shuttle derived vehicles with larger payload capabilities have been studied. Such systems can potentially be obtained from modifications of the Space Shuttle Main Engine (SSME). Concepts based on modifications to the basic engine include an SSME-35 for low altitude operation with liquid rocket boosters and an SSME-150 for operation over the complete altitude range as might be required in a single-stage-to-orbit vehicle application. Another modification would provide operation with a hydrocarbon fuel instead of hydrogen.
The use of a recoverable liquid rocket booster (LRB) system to replace the existing solid rocket booster (SRB) system for the shuttle was studied. Historical weight estimating relationships were developed for the LRB using Saturn technology and modified as required. Mission performance was computed using February 1975 shuttle configuration groundrules to allow reasonable comparison of the existing shuttle with the study designs. The launch trajectory was constrained to pass through both the RTLS/AOA and main engine cut off points of the shuttle reference mission 1. Performance analysis is based on a point design trajectory model which optimizes initial tilt rate and exoatmospheric pitch profile. A gravity turn was employed during the boost phase in place of the shuttle angle of attack profile. Engine throttling add/or shutdown was used to constrain dynamic pressure and/or longitudinal acceleration where necessary. Four basic configurations were investigated: a parallel burn vehicle with an F-1 engine powered LRB; a parallel burn vehicle with a high pressure engine powered LRB; a series burn vehicle with a high pressure engine powered LRB. The relative sizes of the LRB and the ET are optimized to minimize GLOW in most cases.
Historical weight estimating relationships were developed for the liquid rocket booster (LRB) using Saturn technology, and modified as required to support the EDIN05 study. Mission performance was computed using February 1975 shuttle configuration groundrules to allow reasonable comparison of the existing shuttle with the EDIN05 designs. The launch trajectory was constrained to pass through both the RTLS/AOA and main engine cut-off points. Performance analysis was based on a point design trajectory model which optimized initial tilt rate and exo-atmospheric pitch profile. A gravity turn was employed during the boost phase in place of the shuttle angle-of-attack profile. Engine throttling add/or shutdown was used to constrain dynamic pressure and/or longitudinal acceleration where necessary.
A flow diverter valve applicable to any fluid flow system requiring rapid bleed or bypass is disclosed. Examples of application of the flow diverter valve to a liquid rocket and a turbojet aircraft engine are given. Features of the valve include: (1) an independent fluid source is used to activate the flow diverter valve toward its closed position during its initial stage of travel; (2) the flow diverter port area and size is unlimited and the valve travel is unlimited; and (3) the valve housing is fabricated such that the valve can be a one step valve, a two step valve, or include as many steps as are found desirable.
A summary of the design analyses for a liquid rocket injector using oxygen and RP-1 propellants at high chamber pressures of 20,682 kPa (3000 psia) is presented. This analytical investigation includes combustion efficiency versus injector element type, combustion stability, and combustor cooling requirements. The design and fabrication of a subscale injector/acoustic resonantor assembly capable of providing a nominal thrust of 222K N (50,000 lbF) is presented.
The rotordynamic characteristics of turbomachinery are known to depend on the forces developed due to relative motion between the rotor and the housing. For example, the critical speed locations generally depend on the bearing stiffnesses, seal dampling influences rotor stability and bearing reaction amplitudes near critical speeds, etc. A systematic examination of the influence of changes in the forces acting on rotors is studied. More specifically, the sensitivity of the rotordynamic characteristics to changes in rotor forces is analyzed. Rotordynamic characteristics of the HPOTP (High Pressure Oxygen Turbopump) and HPFTP (High Pressure Fuel Turbopump) of the SSME (Space Shuttle Main Engine) are investigated. Because of their markedly different rotordynamic characteristics, these units are considered to be representative of a range of possible future liquid rocket engine turbomachinery.
The space shuttle main engine (SSME) presented new requirements in the design of controls for large pump fed liquid rocket engine systems. These requirements were the need for built in full mission support capability, and complexity and flexibility of function not previously needed in this type of application. An engine mounted programmable digital control system was developed to meet these requirements. The engine system and controller and their function are described. Design challenges encountered during the course of development included accommodation for a very severe engine environment, the implementation of redundancy and redundancy management to provide fail operational/fail safe capability, removal of heat from the package, and significant constraints on computer memory size and processing time. The flexibility offered by programmable control reshaped the approach to engine design and development and set the pattern for future controls development in these types of applications.