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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Fabrication of High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner for Advanced Rocket Engines

NARloy-Z alloy (Cu-3 percent, Ag-0.5 percent, Zr) is a state of the art alloy currently used for fabricating rocket engine combustion chamber liners. Research conducted at NASA-MSFC and Penn State – Applied Research Laboratory has shown that thermal conductivity of NARloy-Z can be increased significantly by adding diamonds to form a composite (NARloy-Z-D). NARloy-Z-D is also lighter than NARloy-Z. These attributes make this advanced composite material an ideal candidate for fabricating combustion chamber liner for an advanced rocket engine. Increased thermal conductivity will directly translate into increased turbopump power and increased chamber pressure for improved thrust and specific impulse. This paper describes the process development for fabricating a subscale high thermal conductivity NARloy-Z-D combustion chamber liner using Field Assisted Sintering Technology (FAST). The FAST process uses a mixture of NARloy-Z and diamond powders which is sintered under pressure at elevated temperatures. Several challenges were encountered, i.e., segregation of diamonds, machining the super hard NARloy-Z-D composite, net shape fabrication and nondestructive examination. The paper describes how these challenges were addressed. Diamonds coated with copper (CuD) appear to give the best results. A near net shape subscale combustion chamber liner is being fabricated by diffusion bonding cylindrical rings of NARloy-Z-CuD using the FAST process.

Bhat, Biliyar N.↗
NASA NTRS2016

Fabrication of High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner for Advanced Rocket Engines

This paper describes the process development for fabricating a high thermal conductivity NARloy-Z-Diamond composite (NARloy-Z-D) combustion chamber liner for application in advanced rocket engines. The fabrication process is challenging and this paper presents some details of these challenges and approaches used to address them. Prior research conducted at NASA-MSFC and Penn State had shown that NARloy-Z-40%D composite material has significantly higher thermal conductivity than the state of the art NARloy-Z alloy. Furthermore, NARloy-Z-40 %D is much lighter than NARloy-Z. These attributes help to improve the performance of the advanced rocket engines. Increased thermal conductivity will directly translate into increased turbopump power, increased chamber pressure for improved thrust and specific impulse. Early work on NARloy-Z-D composites used the Field Assisted Sintering Technology (FAST, Ref. 1, 2) for fabricating discs. NARloy-Z-D composites containing 10, 20 and 40vol% of high thermal conductivity diamond powder were investigated. Thermal conductivity (TC) data. TC increased with increasing diamond content and showed 50% improvement over pure copper at 40vol% diamond. This composition was selected for fabricating the combustion chamber liner using the FAST technique.

Bhat, Biliyar N.↗
NASA NTRS2014

High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner For Advanced Rocket Engines

Advanced high thermal conductivity materials research conducted at NASA Marshall Space Flight Center (MSFC) with state of the art combustion chamber liner material NARloy-Z showed that its thermal conductivity can be increased significantly by adding diamond particles and sintering it at high temperatures. For instance, NARloy-Z containing 40 vol. percent diamond particles, sintered at 975C to full density by using the Field assisted Sintering Technology (FAST) showed 69 percent higher thermal conductivity than baseline NARloy-Z. Furthermore, NARloy-Z-40vol. percent D is 30 percent lighter than NARloy-Z and hence the density normalized thermal conductivity is 140 percent better. These attributes will improve the performance and life of the advanced rocket engines significantly. By one estimate, increased thermal conductivity will directly translate into increased turbopump power up to 2X and increased chamber pressure for improved thrust and ISP, resulting in an expected 20 percent improvement in engine performance. Follow on research is now being conducted to demonstrate the benefits of this high thermal conductivity NARloy-Z-D composite for combustion chamber liner applications in advanced rocket engines. The work consists of a) Optimizing the chemistry and heat treatment for NARloy-Z-D composite, b) Developing design properties (thermal and mechanical) for the optimized NARloy-Z-D, c) Fabrication of net shape subscale combustion chamber liner, and d) Hot fire testing of the liner for performance. FAST is used for consolidating and sintering NARlo-Z-D. The subscale cylindrical liner with built in channels for coolant flow is also fabricated near net shape using the FAST process. The liner will be assembled into a test rig and hot fire tested in the MSFC test facility to determine performance. This paper describes the development of this novel high thermal conductivity NARloy-Z-D composite material, and the advanced net shape technology to fabricate the combustion chamber liner. Properties of optimized NARloy-Z-D composite material will also be presented.

Bhat, Biliyar N.↗
NASA NTRS1984

Energy Efficient Engine combustor test hardware detailed design report

The Energy Efficient Engine (E3) Combustor Development effort was conducted as part of the overall NASA/GE E3 Program. This effort included the selection of an advanced double-annular combustion system design. The primary intent was to evolve a design which meets the stringent emissions and life goals of the E3 as well as all of the usual performance requirements of combustion systems for modern turbofan engines. Numerous detailed design studies were conducted to define the features of the combustion system design. Development test hardware was fabricated, and an extensive testing effort was undertaken to evaluate the combustion system subcomponents in order to verify and refine the design. Technology derived from this development effort will be incorporated into the engine combustion system hardware design. This advanced engine combustion system will then be evaluated in component testing to verify the design intent. What is evolving from this development effort is an advanced combustion system capable of satisfying all of the combustion system design objectives and requirements of the E3. Fuel nozzle, diffuser, starting, and emissions design studies are discussed.

Burrus, D. L.↗
NASA NTRS2018

Comparison of Combustion Dynamic Characteristics of Two Advanced Multi-Cup Fuel Injectors

An experimental investigation of the combustion dynamic characteristics of two advanced multi-cup lean direct injectors (LDI) under simulated gas turbine combustor conditions was conducted. The objective was to gain a better understanding of the physical phenomena inside a pressurized flame tube combustion chamber and study the effects of injector flow number on combustion dynamics. The injectors are known as Three-zone Injectors one and two or 3ZI-1 and 3ZI-2, respectively. The injectors were experimentally evaluated at inlet pressures up to 1.724 MPa, non-vitiated air temperatures up to 828K, and adiabatic flame temperatures up to 1975K. Dynamic pressure measurements were taken upstream of the injectors and in the combustion zone. The combustion dynamic behavior of the two injectors was measured over a range of inlet pressures, inlet temperatures, fuel air ratios, and fuel flow splits.

Combustion Dynamics↗
NASA NTRS1995

Method and apparatus for production of powders

Apparatus and method are disclosed for producing oxides of metals and of metal alloys. The metal or alloy is placed in an oxygen atmosphere in a combustion chamber and ignited. Products of the combustion include one or more oxides of the metal or alloy in powdered form. In one embodiment of the invention a feeder is provided whereby material to be oxidized by combustion can be advanced into a combustion chamber continuously. A product remover receives the powder product of the combustion.

Stolzfus, Joel M.↗
NASA NTRS1998

Method and Apparatus for Production of Powders

Apparatus and method are disclosed for producing oxides of metals and of metal alloys. The metal or alloy is placed in an oxygen atmosphere in a combustion chamber and ignited. Products of the combustion include one or more oxides of the metal or alloy in powdered form. In one embodiment of the invention a feeder is provided whereby material to be oxidized by combustion can be advanced into a combustion chamber continuously. A product remover receives the powder product of the combustion.

Storltzfus, Joel M.↗
NASA NTRS1983

Preliminary tests of an advanced high-temperature combustion system

A combustion system has been developed to operate efficiently and with good durability at inlet pressures to 4.05 MPa (40 atm), inlet air temperatures to 900 K, and exhaust gas temperatures to 2480 K. A preliminary investigation of this system was conducted at inlet pressures to 0.94 MPa (9 atm), a nominal inlet air temperature of 560 K, and exhaust gas temperatures to 2135 K. A maximum combustion efficiency of 98.5 percent was attained at a fuel-air ratio of 0.033; the combustion efficiency decreased to about 90 percent as the fuel-air ratio was increased to 0.058. An average liner metal temperature of 915 K, 355 kelvins greater than the nominal inlet air temperature, was reached with an average exhaust gas temperature of 2090 K. The maximum local metal temperature at this condition was about 565 kelvins above the nominal inlet air temperature and decreased to 505 kelvins above with increasing combustor pressure. Tests to determine the isothermal total pressure loss of the combustor showed a liner loss of 1.1 percent and a system loss of 6.5 percent.

Wear, J. D.↗
NASA NTRS1992

Numerical analysis of the hot-gas-side and coolant-side heat transfer in liquid rocket engine combustors

The objective of this paper are to develop a multidisciplinary computational methodology to predict the hot-gas-side and coolant-side heat transfer and to use it in parametric studies to recommend optimized design of the coolant channels for a regeneratively cooled liquid rocket engine combustor. An integrated numerical model which incorporates CFD for the hot-gas thermal environment, and thermal analysis for the liner and coolant channels, was developed. This integrated CFD/thermal model was validated by comparing predicted heat fluxes with those of hot-firing test and industrial design methods for a 40 k calorimeter thrust chamber and the Space Shuttle Main Engine Main Combustion Chamber. Parametric studies were performed for the Advanced Main Combustion Chamber to find a strategy for a proposed combustion chamber coolant channel design.

Wang, Ten-See↗
NASA NTRS1994

Hot-Gas-Slide and Coolant-Side Heat Transfer in Liquid Rocket Engine Combustors

The objectives of this article are to develop a multidisciplinary, computational methodology to predict the hot-gas-side and coolant-side heat transfer in film cooling assisted, regeneratively cooled liquid rocket engine combustors, and to use it in parametric studies to recommend optimized design of the coolant channels for a developmental combustor. An integrated numerical model which incorporates computational fluid dynamics (CFD) for the hot-gas thermal environment, and thermal analysis for the liner and coolant channels, was developed. This integrated CFD/thermal model was validated by comparing predicted heat fluxes with those of hot-firing test and industrial design methods for a 40-k calorimeter thrust chamber and the Space Shuttle Main Engine main combustion chamber. Parametric studies were performed for the advanced main combustion chamber to find a strategy for a proposed coolant channel design.

Ten-see Wang↗
NASA NTRS1997

Shapes of Buoyant and Nonbuoyant Methane Laminar Jet Diffusion Flames

Laminar gas jet diffusion flames represent a fundamental combustion configuration. Their study has contributed to numerous advances in combustion, including the development of analytical and computational combustion tools. Laminar jet flames are pertinent also to turbulent flames by use of the laminar flamelet concept. Investigations into the shapes of noncoflowing microgravity laminar jet diffusion flames have primarily been pursued in the NASA Lewis 2.2-second drop tower, by Cochran and coworkers and by Bahadori and coworkers. These studies were generally conducted at atmospheric pressure; they involved soot-containing flames and reported luminosity lengths and widths instead of the flame-sheet dimensions which are of Greater value to theory evaluation and development. The seminal model of laminar diffusion flames is that of Burke and Schumann, who solved the conservation of momentum equation for a jet flame in a coflowing ambient by assuming the velocity of fuel, oxidizer and products to be constant throughout. Roper and coworkers improved upon this model by allowing for axial variations of velocity and found flame shape to be independent of coflow velocity. Roper's suggestion that flame height should be independent of gravity level is not supported by past or present observations. Other models have been presented by Klajn and Oppenheim, Markstein and De Ris, Villermaux and Durox, and Li et al. The common result of all these models (except in the buoyant regime) is that flame height is proportional to fuel mass flowrate, with flame width proving much more difficult to predict. Most existing flame models have been compared with shapes of flames containing soot, which is known to obscure the weak blue emission of flame sheets. The present work involves measurements of laminar gas jet diffusion flame shapes. Flame images have been obtained for buoyant and nonbuoyant methane flames burning in quiescent air at various fuel flow-rates, burner diameters and ambient pressures. Soot concentrations were minimized by selecting conditions at low flowrates and low ambient pressures; this allows identification of actual flame sheets associated with blue emissions of CH and CO2. The present modeling effort follows that of Roper and is useful in explaining many of the trends observed.

Sunderland, Peter B.↗
NASA NTRS1999

Particle-Image Velocimetry in Microgravity Laminar Jet Diffusion Flames

This paper discusses planned velocity measurements in microgravity laminar jet diffusion flames. These measurements will be conducted using Particle-Image Velocimetry (PIV) in the NASA Glenn 2.2-second drop tower. The observations are of fundamental interest and may ultimately lead to improved efficiency and decreased emissions from practical combustors. The velocity measurements will support the evaluation of analytical and numerical combustion models. There is strong motivation for the proposed microgravity flame configuration. Laminar jet flames are fundamental to combustion and their study has contributed to myriad advances in combustion science, including the development of theoretical, computational and diagnostic combustion tools. Nonbuoyant laminar jet flames are pertinent to the turbulent flames of more practical interest via the laminar flamelet concept. The influence of gravity on these flames is deleterious: it complicates theoretical and numerical modeling, introduces hydrodynamic instabilities, decreases length scales and spatial resolution, and limits the variability of residence time. Whereas many normal-gravity laminar jet diffusion flames have been thoroughly examined (including measurements of velocities, temperatures, compositions, sooting behavior and emissive and absorptive properties), measurements in microgravity gas-jet flames have been less complete and, notably, have included only cursory velocity measurements. It is envisioned that our velocity measurements will fill an important gap in the understanding of nonbuoyant laminar jet flames.

Sunderland, P. B.↗
NASA NTRS2001

Vacuum Plasma Spray of Cu-8Cr-4Nb for Advanced Liquid-Fuel Combustion Chambers

Vacuum plasma spray (VPS) formed Cu-8Cr-4Nb alloy, with low oxygen, exhibits higher strength at room and elevated temperature than material formed by extrusion. The VPS formed material exhibits slightly lower ductility than the extruded material. VPS forming of Cu-8Cr-4Nb can be used to produce near net structures with mechanical properties comparable to current extruded material.

Zimmerman, F.↗
NASA NTRS2015

Advanced Booster Liquid Engine Combustion Stability

Combustion instability is a phenomenon in liquid rocket engines caused by complex coupling between the time-varying combustion processes and the fluid dynamics in the combustor. Consequences of the large pressure oscillations associated with combustion instability often cause significant hardware damage and can be catastrophic. The current combustion stability assessment tools are limited by the level of empiricism in many inputs and embedded models. This limited predictive capability creates significant uncertainty in stability assessments. This large uncertainty then increases hardware development costs due to heavy reliance on expensive and time-consuming testing.

Tucker, Kevin↗
NASA NTRS1999

Research Data Acquired in World-Class, 60-atm Subsonic Combustion Rig

NASA Lewis Research Center's new, world-class, 60-atmosphere (atm) combustor research facility, the Advanced Subsonic Combustion Rig (ASCR), is in operation and producing highly unique research data. Specifically, data were acquired at high pressures and temperatures representative of future subsonic engines from a fundamental flametube configuration with an advanced fuel injector. The data acquired include exhaust emissions as well as pressure and temperature distributions. Results to date represent an improved understanding of nitrous oxide (NOx) formation at high pressures and temperatures and include an NOx emissions reduction greater than 70 percent with an advanced fuel injector at operating pressures to 800 pounds per square inch absolute (psia). ASCR research is an integral part of the Advanced Subsonic Technology (AST) Propulsion Program. This program is developing critical low-emission combustion technology that will result in the next generation of gas turbine engines producing 50 to 70 percent less NOx emissions in comparison to 1996 International Civil Aviation Organization (ICAO) limits. The results to date indicate that the AST low-emission combustor goals of reducing NOx emissions by 50 to 70 percent are feasible. U.S. gas turbine manufacturers have started testing the low-emissions combustors at the ASCR. This collaborative testing will enable the industry to develop low-emission combustors at the high pressure and temperature conditions of future subsonic engines. The first stage of the flametube testing has been implemented. Four GE Aircraft Engines low-emissions fuel injector concepts, three Pratt & Whitney concepts, and two Allison concepts have been tested at Lewis ASCR facility. Subsequently, the flametube was removed from the test stand, and the sector combustor was installed. The testing of low emissions sector has begun. Low-emission combustors developed as a result of ASCR research will enable U.S. engine manufacturers to compete on a worldwide basis by producing environmentally acceptable commercial engines.

Lee, Chi-Ming↗
NASA NTRS1984

Energy Efficient Engine (E3) combustion system component technology performance report

The Energy Efficient Engine (E3) combustor effort was conducted as part of the overall NASA/GE E3 Program. This effort included the selection of an advanced double-annular combustion system design. The primary intent of this effort was to evolve a design that meets the stringent emissions and life goals of the E3, as well as all of the usual performance requirements of combustion systems for modern turbofan engines. Numerous detailed design studies were conducted to define the features of the combustion system design. Development test hardware was fabricated, and an extensive testing effort was undertaken to evaluate the combustion system subcomponents in order to verify and refine the design. Technology derived from this effort was incorporated into the engine combustion hardware design. The advanced engine combustion system was then evaluated in component testing to verify the design intent. What evolved from this effort was an advanced combustion system capable of satisfying all of the combustion system design objectives and requirements of the E3.

Burrus, D. L.↗
NASA NTRS1985

SSME fuel preburner phase 1/phase 2+ comparison

An analytical comparison of the predicted combustion flowfields for the Phase 1 and Phase 2+ fuel preburner configurations using an advanced CFD combustion code is currently underway at Rocketdyne. The Phase 2+ injector has a modified element design. The redesigned element provides for improved atomization through a shift in the injector element/face bleed flow split while maintaining an acceptable pressure drop. Cold-flow tests of the new design have been encouraging. As a complement to those tests, the Advanced Rocket Injector Combustor Code (ARICC) was selected to conduct a detailed combustion flowfield simulation. ARICC models two-dimensional (or axisymmetric), transient, turbulent, two-phase mixing and combustion flowfields. It is derived from a member of the Los Alamos ICEd-ALE family of codes. Unique features of ARICC include explicit representation of the coaxial LOX jet and hydrogen gas flows, distributed atomization processes, droplet breakup, and supercritical vaporation processes. Predictions of temperature and OH concentration profiles for the Phase 1 and Phase 2+ injector flowfields indicate a trend toward more uniform temperature distributions and shorter flame lengths with the Phase 2+ design.

Jensen, R. J.↗