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NASA NTRS2007

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗

NASA NTRS1990

Two-dimensional Euler and Navier-Stokes Time accurate simulations of fan rotor flows

Two numerical methods are presented which describe the unsteady flow field in the blade-to-blade plane of an axial fan rotor. These methods solve the compressible, time-dependent, Euler and the compressible, turbulent, time-dependent, Navier-Stokes conservation equations for mass, momentum, and energy. The Navier-Stokes equations are written in Favre-averaged form and are closed with an approximate two-equation turbulence model with low Reynolds number and compressibility effects included. The unsteady aerodynamic component is obtained by superposing inflow or outflow unsteadiness to the steady conditions through time-dependent boundary conditions. The integration in space is performed by using a finite volume scheme, and the integration in time is performed by using k-stage Runge-Kutta schemes, k = 2,5. The numerical integration algorithm allows the reduction of the computational cost of an unsteady simulation involving high frequency disturbances in both CPU time and memory requirements. Less than 200 sec of CPU time are required to advance the Euler equations in a computational grid made up of about 2000 grid during 10,000 time steps on a CRAY Y-MP computer, with a required memory of less than 0.3 megawords.

Boretti, A. A.↗

NASA NTRSDate not supplied

Calibration of a V-Cone for Low Mass Flows For Small Core Compressor Research

Advancements in core compressor technologies are necessary for next generation, high Overall Pressure Ratio (OPR) turbofan engines. High pressure compressors (HPCs) for future engines are being designed with exit corrected mass flow rates less than 2.25 kg/s (5 lbm/s). In order to accurately measure the performance of these advanced designs, high accuracy measurements are needed in test facilities. The W7 High Speed Multistage Axial Compressor Facility at NASA Glenn Research Center has been used to acquire data for advanced compressor designs. This facility utilizes an advanced differential pressure flow meter called a V-Cone. The facility has historically tested components with physical mass flow rates in the range of 27 to 45 kg/s (60 to 100 lbm/s). As such, when the V-Cone was calibrated prior to installation, the calibrations focused on higher mass flow rates, and uncertainties in that regime range from 0.5% to 0.85%. However, for low mass flow rates under 9 kg/s (20 lbm/s), expected in tests of advanced high OPR HPCs rear stages, the uncertainties of the V-Cone exceed 2.5%. To address this, using a method similar to that utilized by the National Institute of Standards and Technology, an array of Critical Flow Venturi Nozzles (CFVs) was installed in the W7 test section and used to calibrate the V-Cone in 0.5 kg/s (1 lbm/s) increments up to 10.5 kg/s (23 lbm/s). This effort details the measurements and uncertainties associated with this calibration which resulted in a final uncertainty of the V-Cone measurements under 1%.

Measurement Uncertainty↗

NASA NTRS1951

Over-all Performance of J35-A-23 Two-stage Turbine

Over-all performance of a two-stage turbine from a J35-A-23 turbojet engine is presented. Limiting blade loading restricted work output to approximately 95 percent of the design value. The brake internal efficiency at design operating conditions was approximately 0.75. maximum brake internal efficiency at off-design conditions was between 0.81 and 0.82.

TURBINES, GAS - PERFORMANCE↗

NASA NTRS2002

Expression of the ctenophore Brain Factor 1 forkhead gene ortholog (ctenoBF-1) mRNA is restricted to the presumptive mouth and feeding apparatus: implications for axial organization in the Metazoa

Ctenophores are thoroughly modern animals whose ancestors are derived from a separate evolutionary branch than that of other eumetazoans. Their major longitudinal body axis is the oral-aboral axis. An apical sense organ, called the apical organ, is located at the aboral pole and contains a highly innervated statocyst and photodetecting cells. The apical organ integrates sensory information and controls the locomotory apparatus of ctenophores, the eight longitudinal rows of ctene/comb plates. In an effort to understand the developmental and evolutionary organization of axial properties of ctenophores we have isolated a forkhead gene from the Brain Factor 1 (BF-1) family. This gene, ctenoBF-1, is the first full-length nuclear gene reported from ctenophores. This makes ctenophores the most basal metazoan (to date) known to express definitive forkhead class transcription factors. Orthologs of BF-1 in vertebrates, Drosophila, and Caenorhabditis elegans are expressed in anterior neural structures. Surprisingly, in situ hybridizations with ctenoBF-1 antisense riboprobes show that this gene is not expressed in the apical organ of ctenophores. CtenoBF-1 is expressed prior to first cleavage. Transcripts become localized to the aboral pole by the 8-cell stage and are inherited by ectodermal micromeres generated from this region at the 16- and 32-cell stages. Expression in subsets of these cells persists and is seen around the edge of the blastopore (presumptive mouth) and in distinct ectodermal regions along the tentacular poles. Following gastrulation, stomodeal expression begins to fade and intense staining becomes restricted to two distinct domains in each tentacular feeding apparatus. We suggest that the apical organ is not homologous to the brain of bilaterians but that the oral pole of ctenophores corresponds to the anterior pole of bilaterian animals.

Non-NASA Center↗

NASA NTRS1992

Aerodynamics of the advanced launch system (ALS) propulsion and avionics (P/A) module

This paper discusses the design and testing of candidate Advanced Launch System (ALS) Propulsion and Avionics (P/A) Module configurations. The P/A Module is a key element of future launch systems because it is essential to the recovery and reuse of high-value propulsion and avionics hardware. The ALS approach involves landing of first stage (booster) and/or second stage (core) P/A modules near the launch site to minimize logistics and refurbishment cost. The key issue addressed herein is the aerodynamic design of the P/A module, including the stability characteristics and the lift-to-drag (L/D) performance required to achieve the necessary landing guidance accuracy. The reference P/A module configuration was found to be statically stable for the desired flight regime, to provide adequate L/D for targeting, and to have effective modulation of the L/D performance using a body flap. The hypersonic aerodynamic trends for nose corner radius, boattail angle and body flap deflections were consistent with pretest predictions. However, the levels for the L/D and axial force for hypersonic Mach numbers were overpredicted by impact theories.

Ferguson, Stan↗

NASA NTRS1956

Component Performance Investigation of J71 Experimental Turbine. Iv-effect of First-stator Adjustment; Over-all Performance of J71-97 Turbine with 132-percent-design Stator Area

An experimental invesitgation of the effect of increasing the first-stator area of the J71-97 experimental three-stage turbine from 97 percent of design to 132 percent revealed (1) the maximum efficiency obtained decreased from 0.891 to 0.869, (2) the choking equivalent weight flows increased by approximately 13.6 percent, and (3) at the turbine match points required to maintain the compressor at constant design equivalent conditions the turbine efficiency decreased from 0.87 to 0.86.

TURBINES -ALLISON J-71↗

NASA NTRS2004

Aligning Arrays of Lenses and Single-Mode Optical Fibers

A procedure now under development is intended to enable the precise alignment of sheet arrays of microscopic lenses with the end faces of a coherent bundle of as many as 1,000 single-mode optical fibers packed closely in a regular array (see Figure 1). In the original application that prompted this development, the precise assembly of lenses and optical fibers serves as a single-mode spatial filter for a visible-light nulling interferometer. The precision of alignment must be sufficient to limit any remaining wavefront error to a root-mean-square value of less than 1/10 of a wavelength of light. This wavefront-error limit translates to requirements to (1) ensure uniformity of both the lens and fiber arrays, (2) ensure that the lateral distance from the central axis of each lens and the corresponding optical fiber is no more than a fraction of a micron, (3) angularly align the lens-sheet planes and the fiber-bundle end faces to within a few arc seconds, and (4) axially align the lenses and the fiber-bundle end faces to within tens of microns of the focal distance. Figure 2 depicts the apparatus used in the alignment procedure. The beam of light from a Zygo (or equivalent) interferometer is first compressed by a ratio of 20:1 so that upon its return to the interferometer, the beam will be magnified enough to enable measurement of wavefront quality. The apparatus includes relay lenses that enable imaging of the arrays of microscopic lenses in a charge-coupled-device (CCD) camera that is part of the interferometer. One of the arrays of microscopic lenses is mounted on a 6-axis stage, in proximity to the front face of the bundle of optical fibers. The bundle is mounted on a separate stage. A mirror is attached to the back face of the bundle of optical fibers for retroreflection of light. When a microscopic lens and a fiber are aligned with each other, the affected portion of the light is reflected back by the mirror, recollimated by the microscopic lens, transmitted through the relay lenses and the beam compressor/expander, then split so that half goes to a detector and half to the interferometer. The output of the detector is used as a feedback control signal for the six-axis stage to effect alignment.

Liu, Duncan↗

NASA NTRS2013

Further Development of Rotating Rake Mode Measurement Data Analysis

The Rotating Rake mode measurement system was designed to measure acoustic duct modes generated by a fan stage. After analysis of the measured data, the mode amplitudes and phases were quantified. For low-speed fans within axisymmetric ducts, mode power levels computed from rotating rake measured data would agree with the far-field power levels on a tone by tone basis. However, this agreement required that the sound from the noise sources within the duct propagated outward from the duct exit without reflection at the exit and previous studies suggested conditions could exist where significant reflections could occur. To directly measure the modes propagating in both directions within a duct, a second rake was mounted to the rotating system with an offset in both the axial and the azimuthal directions. The rotating rake data analysis technique was extended to include the data measured by the second rake. The analysis resulted in a set of circumferential mode levels at each of the two rake microphone locations. Radial basis functions were then least-squares fit to this data to obtain the radial mode amplitudes for the modes propagating in both directions within the duct. The fit equations were also modified to allow evanescent mode amplitudes to be computed. This extension of the rotating rake data analysis technique was tested using simulated data, numerical code produced data, and preliminary in-duct measured data.

Dahl, Milo D.↗

NASA NTRS2004

Momentum Flux Measurements Using an Impact Thrust Stand

A device has been developed to measure the force caused by a beam of charged and neutral particles impacting a target plate. This device, an impact thrust stand, was developed to allow thrusters, during early stages of development, to be quickly and easily exhausted and compared to other thrusters. Since some thruster concepts are tested using laboratory equipment that is heavy and cumbersome, measuring the momentum flux of the particles in the plume can be much simpler than placing the entire thruster on a thrust stand. Conservation of momentum requires the momentum flux measured in the plume to be related to the thrust produced by the thruster. The impact thrust stand was designed to be placed in the plume of an electric thruster and has been tested and compared to the thrust measured from a Hall thruster placed on a pendulum thrust stand. Force measurements taken at several axial locations in the magnetic nozzle region of the Variable Specific Impulse Magnetoplasma Rocket will be presented.

Chavers, Greg↗

NASA NTRS1972

New technology in turbine aerodynamics

A cursory review is presented of some of the recent work that has been done in turbine aerodynamic research at NASA-Lewis Research Center. Topics discussed include the aerodynamic effect of turbine coolant, high work-factor (ratio of stage work to square of blade speed) turbines, and computer methods for turbine design and performance prediction. An extensive bibliography is included. Experimental cooled-turbine aerodynamics programs using two-dimensional cascades, full annular cascades, and cold rotating turbine stage tests are discussed with some typical results presented. Analytically predicted results for cooled blade performance are compared to experimental results. The problems and some of the current programs associated with the use of very high work factors for fan-drive turbines of high-bypass-ratio engines are discussed. Turbines currently being investigated make use of advanced blading concepts designed to maintain high efficiency under conditions of high aerodynamic loading. Computer programs have been developed for turbine design-point performance, off-design performance, supersonic blade profile design, and the calculation of channel velocities for subsonic and transonic flow fields. The use of these programs for the design and analysis of axial and radial turbines is discussed.

Glassman, A. J.↗

DOE OSTI2025

Cooling Design and Thermal Analysis for Thermal Shields of a Cryocooler-Cooled Superconducting ECR Ion Source MARS-D Magnet

Here, a demonstrative NbTi based Mixed Axial and Radial field System (MARS-D) is being developed for a next-Generation Electron Cyclotron Resonance Ion Source (ECRIS) at Lawrence Berkeley National Laboratory (LBL), which employs a novel closed-loop coil design scheme that more efficiently utilizes conductor fields and extend the application of NbTi for high frequency (up to 45 GHz) ECR operation. The NbTi MARS-D magnet consists of a single hexagonally shaped closed-loop coil and a set of auxiliary solenoids. A cryostat for cooling the MARS-D magnet is under design at LBL. The MARS-D magnet working around 4.2 K will be bath-cooled in liquid helium using multiple two-stage cryocoolers. An intermediate temperature thermal radiation shield is adopted to reduce the heat leakage imposed on 4.2 K coil cold mass from room temperature. The thermal shield is conduction-cooled by the first-stage cold heads of four two-stage cryocoolers and the cold head of a single-stage cryocooler shared with nine binary leads. The temperature in the area of the shield that warm ends of HTS leads are mounted on is expected no higher than 60 K, which is limited by maximum allowable working temperature of HTS leads. The paper presents thermal analysis on the thermal radiation shield including heat loads and effects of eddy current induced during quench on its material selection.

ECRIS↗

NASA NTRS2008

Elastic-Plastic Fracture Mechanics Analysis of Critical Flaw Size in ARES I-X Flange-to-Skin Welds

NASA's Ares 1 Upper Stage Simulator (USS) is being fabricated from welded A516 steel. In order to insure the structural integrity of these welds it is of interest to calculate the critical initial flaw size (CIFS) to establish rational inspection requirements. The CIFS is in turn dependent on the critical final flaw size (CFS), as well as fatigue flaw growth resulting from transportation, handling and service-induced loading. These calculations were made using linear elastic fracture mechanics (LEFM), which are thought to be conservative because they are based on a lower bound, so called elastic, fracture toughness determined from tests that displayed significant plasticity. Nevertheless, there was still concern that the yield magnitude stresses generated in the flange-to-skin weld by the combination of axial stresses due to axial forces, fit-up stresses, and weld residual stresses, could give rise to significant flaw-tip plasticity, which might render the LEFM results to be non-conservative. The objective of the present study was to employ Elastic Plastic Fracture Mechanics (EPFM) to determine CFS values, and then compare these values to CFS values evaluated using LEFM. CFS values were calculated for twelve cases involving surface and embedded flaws, EPFM analyses with and without plastic shakedown of the stresses, LEFM analyses, and various welding residual stress distributions. For the cases examined, the computed CFS values based on elastic analyses were the smallest in all instances where the failures were predicted to be controlled by the fracture toughness. However, in certain cases, the CFS values predicted by the elastic-plastic analyses were smaller than those predicted by the elastic analyses; in these cases the failure criteria were determined by a breakdown in stress intensity factor validity limits for deep flaws (a greater than 0.90t), rather than by the fracture toughness. Plastic relaxation of stresses accompanying shakedown always increases the calculated CFS values compared to the CFS values determined without shakedown. Thus, it is conservative to ignore shakedown effects.

Chell, G. Graham↗

DOE OSTI2023

A Hybrid Transmitter With Voltage-Mode SST Preemphasis and Current-Mode Transmitter Equalization Capable of Operating at 77 K in DUNE

The Deep Underground Neutrino Experiment (DUNE) requires that the front-end transmitters operate at cryogenic temperature and drive 25–35 m long twin-axial (twinax) cables. Here, to compensate the frequency-dependent channel loss over the long cables and alleviate the de-emphasizing of the low-frequency signal magnitude, a hybrid of a current-mode (CM) transmitter equalization (TXEQ) and a voltage-mode (VM) preemphasis is proposed. The TXEQ employs a finite-impulse response (FIR) filter to boost the high-frequency components while de-emphasizing the low-frequency signal magnitude, thereby flattening the overall channel frequency response and reducing the intersymbol interference (ISI). The VM preemphasis is proposed to further mitigate ISI by boosting the high-frequency portion without degrading the signal magnitude, allowing for high signal swing. The main driver utilizes VM source-series-terminated (SST) output stages, which offers higher signal swing and better power efficiency than the conventional CM logic (CML) drivers. To ensure the lifetime and reliability at cryogenic temperature, the transmitter is implemented in a 65-nm CMOS process operating at 1.1 V of supply voltage and employing transistors with larger than minimum lengths. Silicon measurement results at 77 K have validated the proposed approaches.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1999

Water Flow Performance of a Superscale Model of the Fastrac Liquid Oxygen Pump

As part of the National Aeronautics and Space Administration's ongoing effort to lower the cost of access to space, the Marshall Space Flight Center has developed a rocket engine with 60,000 pounds of thrust for use on the Reusable Launch Vehicle technology demonstrator slated for launch in 2000. This gas generator cycle engine, known as the Fastrac engine, uses liquid oxygen and RP-1 for propellants and includes single stage liquid oxygen and RP-1 pumps and a single stage supersonic turbine on a common shaft. The turbopump design effort included the first use and application of new suction capability prediction codes and three-dimensional blade generation codes in an attempt to reduce the turbomachinery design and certification costs typically associated with rocket engine development. To verify the pump's predicted cavitation performance, a water flow test of a superscale model of the Fastrac liquid oxygen pump was conducted to experimentally evaluate the liquid oxygen pump's performance at and around the design point. The water flow test article replicated the flow path of the Fastrac liquid oxygen pump in a 1.582x scale model, including scaled seal clearances for correct leakage flow at a model operating speed of 5000 revolutions per minute. Flow entered the 3-blade axial-flow inducer, transitioned to a shrouded, 6-blade radial impeller, and discharged into a vaneless radial diffuser and collection volute. The test article included approximately 50 total and static pressure measurement locations as well as flush-mounted, high frequency pressure transducers for complete mapping of the pressure environment. The primary objectives of the water flow test were to measure the steady-state and dynamic pressure environment of the liquid oxygen pump versus flow coefficient, suction specific speed, and back face leakage flow rate. Results showed excellent correlation between the predicted and experimentally measured pump head rise at low suction specific speeds. Likewise, only small circumferential variations in steady-state impeller exit and radial diffuser pressure distributions were observed from 80% to 120% of the design flow coefficient, matching the computational predictions and confirming that the integrated design approach has minimized any exit volute-induced distortions. The test article exhibited suction performance trends typically observed in inducer designs with virtually constant head rise with decreasing inlet pressure until complete pump head breakdown. Unfortunately, the net positive suction head at 3% head fall-off occurred far below that predicted at all tested flow coefficients, resulting in a negative net positive suction head margin at the design point in water. Additional testing to map the unsteady pressure environment was conducted and interesting rotating phenomena at the inducer inlet were observed. These rotating phenomena's cell numbers, direction, and speed were correlated with pump operating parameters. The impact of the unsteady phenomena and their corresponding energy losses on the unexpectedly poor pump performance is also discussed.

Skelley, Stephen↗

NASA NTRS2001

Water Flow Performance of a Superscale Model of the Fastrac Liquid Oxygen Pump

As part of the National Aeronautics and Space Administration's ongoing effort to lower the cost of access to space, the Marshall Space Flight Center has developed a rocket engine with 60,000 pounds of thrust for use on the Reusable Launch Vehicle technology demonstrator slated for launch in 2000. This gas generator cycle engine, known as the Fastrac engine, uses liquid oxygen and RP-1 for propellants and includes single stage liquid oxygen and RP-1 pumps and a single stage supersonic turbine on a common shaft. The turbopump design effort included the first use and application of new suction capability prediction codes and three-dimensional blade generation codes in an attempt to reduce the turbomachinery design and certification costs typically associated with rocket engine development. To verify the pump's predicted cavitation performance, a water flow test of a superscale model of the Fastrac liquid oxygen pump was conducted to experimentally evaluate the liquid oxygen pump's performance at and around the design point. The water flow test article replicated the flow path of the Fastrac liquid oxygen pump in a 1.582x scale model, including scaled seal clearances for correct leakage flow at a model operating speed of 5000 revolutions per minute. Flow entered the 3-blade axial-flow inducer, transitioned to a shrouded, 6- blade radial impeller, and discharged into a vaneless radial diffuser and collection volute. The test article included approximately 50 total and static pressure measurement locations as well as flush-mounted, high frequency pressure transducers for complete mapping of the pressure environment. The primary objectives of the water flow test were to measure the steady-state and dynamic pressure environment of the liquid oxygen pump versus flow coefficient, suction specific speed, and back face leakage flow rate. Initial results showed acceptable correlation between the predicted and experimentally measured pump head rise at low suction specific speeds. Likewise, only small circumferential variations in steady-state were observed from 80% to 120% of the design flow coefficient, matching the computational predictions and confirming that the integrated design approach has minimized any exit volute-induced distortions. The test article exhibited suction performance trends typically observed in inducer designs with virtually constant head rise with decreasing inlet pressure until complete pump head breakdown. Unfortunately, the net positive suction head at 3% head fall-off occurred far below that predicted at all tested flow coefficients, resulting in a negative net positive suction head margin at the design point in water. Additional testing to map the unsteady pressure environment was conducted and cavitation-induced flow disturbances at the inducer inlet were observed. Two distinct disturbances were identified, one rotating and one stationary relative to the fixed frame of reference, while the transition from one regime to the next produced significant effects on the steady state pump performance. The impact of the unsteady phenomena and the corresponding energy losses on the unexpectedly poor pump performance is also discussed.

Skelley, Stephen↗

NASA NTRS2010

Validation of Supersonic Film Cooling Modeling for Liquid Rocket Engine Applications

Topics include: upper stage engine key requirements and design drivers; Calspan "stage 1" results, He slot injection into hypersonic flow (air); test articles for shock generator diagram, slot injector details, and instrumentation positions; test conditions; modeling approach; 2-d grid used for film cooling simulations of test article; heat flux profiles from 2-d flat plate simulations (run #4); heat flux profiles from 2-d backward facing step simulations (run #43); isometric sketch of single coolant nozzle, and x-z grid of half-nozzle domain; comparison of 2-d and 3-d simulations of coolant nozzles (run #45); flowfield properties along coolant nozzle centerline (run #45); comparison of 3-d CFD nozzle flow calculations with experimental data; nozzle exit plane reduced to linear profile for use in 2-d film-cooling simulations (run #45); synthetic Schlieren image of coolant injection region (run #45); axial velocity profiles from 2-d film-cooling simulation (run #45); coolant mass fraction profiles from 2-d film-cooling simulation (run #45); heat flux profiles from 2-d film cooling simulations (run #45); heat flux profiles from 2-d film cooling simulations (runs #47, #45, and #47); 3-d grid used for film cooling simulations of test article; heat flux contours from 3-d film-cooling simulation (run #45); and heat flux profiles from 3-d and 2-d film cooling simulations (runs #44, #46, and #47).

Morris, Christopher I.↗

NASA NTRS2018

Comparison of Single-Element and Multi-Element Oxygen/RP-1 Oxidizer-Rich Staged-Combustion Injector Hot-Fire Test Results

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/hydrocarbon propellant multi-element integrated test article that included an oxidizer-rich oxygen/hydrocarbon propellant preburner and a staged-combustion main injector. Also as part of this project, the Air Force Research Laboratory fabricated single-element main injectors of the same designs as used in the NASA multi-element injectors, and tested them in a staged-combustion integrated test article that used an oxidizer-rich oxygen/hydrogen propellant preburner. Final results of the multi-element and single-element staged-combustion main injector test programs are described in companion papers at this JANNAF meeting. The design, development, and preliminary test results of these main injectors have also been described in previous JANNAF papers. The main injector element designs were all based on relatively conventional gas-centered swirl coaxial injector element configurations such as used in Russian RD-170 and NK-33 engines, and planned for use in future U.S.-built experimental engine systems such as the Hydrocarbon Boost program demonstration engine. Four different elements were tested in both the multi-element and single-element main injectors, at similar combustion chamber pressures, chamber contraction ratios, and mixture ratios. Variations of the element features included recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. This paper compares the hydraulics, combustion performance, stability, and compatibility characteristics of the single-element and multi-element injectors operated at similar conditions. The single-element hardware is shown to have captured a significant level of the operability of the multi-element hardware.

Hulka, J. R.↗