Fuel Flow Analysis of a Micro Turbine Engine
Student exit presentation based on poster done during the Summer session.
turbine pumps↗
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Simplex turbopump design
Turbomachinery used in liquid rocket engines typically are composed of complex geometries made from high strength-to-weight super alloys and have long design and fabrication cycle times (3 to 5 years). A simple, low-cost turbopump is being designed in-house to demonstrate the ability to reduce the overall cost to $500K and compress life cycle time to 18 months. The simplex turbopump was designed to provide a discharge pressure of 1500 psia of liquid oxygen at 90 lbm/s. The turbine will be powered by gaseous oxygen. This eliminates the need for an inter-propellant seal typically required to separate the fuel-rich turbine gases from the liquid oxygen pump components. Materials used in the turbine flow paths will utilize existing characterized metals at 800 deg R that are compatible with a warm oxygen environment. This turbopump design would be suitable for integration with a 40 K pound thrust hybrid motor that provides warm oxygen from a tapped-off location to power the turbine. The preliminary and detailed analysis was completed in a year by a multiple discipline, concurrent engineering team. Manpower, schedule, and cost data were tracked during the process for a comparison to the initial goal. The Simplex hardware is the procurement cycle with the expectation of the first test to occur approximately 1.5 months behind the original schedule goal.
Marsh, Matt↗
Mars Ascent Vehicle Hybrid Propulsion Development
Hybrid propulsion is being investigated as a propulsion method for a possible Mars Ascent Vehicle (MAV) application. MAV is part of a proposed larger Mars Sample Return (MSR) campaign plan to bring samples from Mars to earth for examination. The Mars Ascent Vehicle would launch Mars surface samples found and packaged by the Mars 2020 mission to orbit around Mars. This version of hybrid propulsion is based on a wax based solid fuel, called SP7A, and a Mixed Oxides of Nitrogen oxidizer, MON-25. SP7 is a new fuel formulation developed by Space Propulsion Group and was modified for this application to be resistant to Mars temperature extremes and modified again to lower the regression rate to become SP7A. MON-25 was chosen for its low freezing temperature. Due to cost constraints, MON-3 was the oxidizer used during testing through 2018. In 2019, full scale hybrid testing with MON-25 commenced in Mojave, CA by Whittinghill Aerospace. One flight motor will be subjected to thermal cycling in a vacuum and later fired in a vacuum to demonstrate the proposed Liquid Injection Thrust Vector Control system performance at White Sands Test Facility (WSTF). In addition, there will be MON-25 characterization work done at Purdue University and WSTF. Additional testing of subscale and full scale motors will be conducted with MON-3 with fuel grain stress, fuel grain support and case design test objectives by Space Propulsion Group Inc. of Butte, MT. This paper documents some of the testing, issues and accomplishments with the MAV hybrid propulsion option that is being considered (along with a two-stage solid propulsion option).
Story, G. T.↗
System-Level Testing of the Advanced Stirling Radioisotope Generator Engineering Hardware
To support future NASA deep space missions, a radioisotope power system utilizing Stirling power conversion technology was under development. This development effort was performed under the joint sponsorship of the Department of Energy and NASA, until its termination at the end of 2013 due to budget constraints. The higher conversion efficiency of the Stirling cycle compared with that of the Radioisotope Thermoelectric Generators (RTGs) used in previous missions (Viking, Pioneer, Voyager, Galileo, Ulysses, Cassini, Pluto New Horizons and Mars Science Laboratory) offers the advantage of a four-fold reduction in Pu-238 fuel, thereby extending its limited domestic supply. As part of closeout activities, system-level testing of flight-like Advanced Stirling Convertors (ASCs) with a flight-like ASC Controller Unit (ACU) was performed in February 2014. This hardware is the most representative of the flight design tested to date. The test fully demonstrates the following ACU and system functionality: system startup; ASC control and operation at nominal and worst-case operating conditions; power rectification; DC output power management throughout nominal and out-of-range host voltage levels; ACU fault management, and system command / telemetry via MIL-STD 1553 bus. This testing shows the viability of such a system for future deep space missions and bolsters confidence in the maturity of the flight design.
Deep space↗
The role of fracture mechanics in the design of fuel tanks in space vehicles
With special reference to design of fuel tanks in space vehicles, the principles of fracture mechanics are reviewed. An approximate but extremely simple relationship is derived among the operating stress level, the length of crack, and the number of cycles of failure. Any one of the variables can be computed approximately from the knowledge of the other two, if the loading schedule (mission of the tank) is not greatly altered. Two sample examples illustrating the procedures of determining the allowable safe operating stress corresponding to a set of assumed loading schedule are included. The selection of sample examples is limited by the relatively meager available data on the candidate material for various stress ratios in the cycling.
Denton, S. J.↗
ENGINEL: A single rotor turbojet engine cycle match performance program
ENGINEL is a computer program which was developed to generate the design and off-design performance of a single rotor turbojet engine with or without afterburning using a cycle match procedure. It is capable of producing engine performance over a wide range of altitudes and Mach numbers. The flexibility, of operating with a variable geometry turbine, for improved off-design fuel consumption or with a fixed geometry turbine as in conventional turbojets, has been incorporated. In addition, the option of generation engine performance with JP4, liquid hydrogen or methane as fuel is provided.
Lovell, W. A.↗
Hydrogen-fueled engine
A hydrogen-oxygen fueled internal combustion engine is described, which utilizes an inert gas, such as argon, as a working fluid to increase the efficiency of the engine, eliminate pollution, and facilitate operation of a closed cycle energy system. In a system where sunlight or other intermittent energy source is available to separate hydrogen and oxygen from water, the oxygen and inert gas are taken into a diesel engine into which hydrogen is injected and ignited. The exhaust is cooled so that it contains only water and the inert gas. The inert gas in the exhaust is returned to the engine for use with fresh oxygen, while the water in the exhaust is returned to the intermittent energy source for reconversion to hydrogen and oxygen.
Laumann, E. A.↗
Small gas turbine engine technology
Performance of small gas turbine engines in the 250 to 1,000 horsepower size range is significantly lower than that of large engines. Engines of this size are typically used in rotorcraft, commutercraft, general aviation, and cruise missile applications. Principal reasons for the lower efficiencies of a smaller engine are well known: component efficients are lower by as much as 8 to 10 percentage points because of size effects. Small engines are designed for lower cycle pressures and temperatures because of smaller blading and cooling limitations. The highly developed analytical and manufacturing techniques evolved for large engines are not directly transferrable to small engines. Thus, it was recognized that a focused effort addressing technologies for small engies was needed and could significantly impact their performance. Recently, in-house and contract studies were undertaken at the NASA Lewis Research Center to identify advanced engine cycle and component requirements for substantial performance improvement of small gas turbines for projected year 2000 applications. The results of both in-house research and contract studies are presented. In summary, projected fuel savings of 22 to 42 percent could be obtained. Accompanying direct operating cost reductions of 11 to 17 percent, depending on fuel cost, were also estimated. High payoff technologies are identified for all engine applications, and recent results of experimental research to evolve the high payoff technologies are described.
Niedzwiecki, Richard W.↗
Updated solid-core nuclear thermal propulsion engine trades
This study examined the application of state-of-the-art propulsion and reactor technologies to a near-term solid-core NERVA-based nuclear thermal propulsion system. Updated reactor performance and weight scaling laws were initially derived and input into a nuclear rocket engine system cycle design analysis code. Nuclear Thermal Propulsion (NTP) engine system weight, size, and performance are presented here for a large range of chamber pressures, nozzle area ratios, and thrust levels for three reactor fuel types operating at their corresponding temperatures. Operational characteristics and design features of representative NTP engine concepts are also presented.
Pelaccio, Dennis G.↗
Preliminary assessment of combustion modes for internal combustion wave rotors
Combustion within the channels of a wave rotor is examined as a means of obtaining pressure gain during heat addition in a gas turbine engine. Several modes of combustion are considered and the factors that determine the applicability of three modes are evaluated in detail; premixed autoignition/detonation, premixed deflagration, and non-premixed compression ignition. The last two will require strong turbulence for completion of combustion in a reasonable time in the wave rotor. The compression/autoignition modes will require inlet temperatures in excess of 1500 R for reliable ignition with most hydrocarbon fuels; otherwise, a supplementary ignition method must be provided. Examples of combustion mode selection are presented for two core engine applications that had been previously designed with equivalent 4-port wave rotor topping cycles using external combustion.
Nalim, M. Razi↗
MAP Propulsion System Thermal Design
The propulsion system of the Microwave Anisotropy Probe (MAP) had stringent requirements that made the thermal design unique. To meet instrument stability requirements the system had to be designed to keep temperatures of all components within acceptable limits without heater cycling. Although the spacecraft remains at a fixed 22 sun angle at L2, the variations in solar constant, property degradation, and bus voltage range all significantly affect the temperature. Large portions of the fuel lines are external to the structure and all components are mounted to non-conductive composite structure. These two facts made the sensitivity to the MLI effective emissivity and bus temperature very high. Approximately two years prior to launch the propulsion system was redesigned to meet MAP requirements. The new design utilized hardware that was already installed in order to meet schedule constraints. The spacecraft design and the thermal requirements were changed to compensate for inadequacies of the existing hardware. The propulsion system consists of fuel lines, fill and drain lines/valve, eight thrusters, a HXCM, and a propulsion tank. A voltage regulator was added to keep critical components within limits. Software was developed to control the operational heaters. Trim resistors were put in series with each operational heater circuits and the tank survival heater. A highly sophisticated test program, which included real time model correlation, was developed to determine trim resistors sizes. These trim resistors were installed during a chamber break and verified during thermal balance testing.
Mosier, Carol L.↗
Main Chamber Injectors for Advanced Hydrocarbon Booster Engines
Achieving the highest possible specific impulse has long been a key driver for space launch systems. Recently, more importance has been placed on the need for increased reliability and streamlined launch operations. These general factors along with more specific mission requirements have provided a new focus that is centered on the oxidizer rich staged combustion (ORSC) cycle. Despite a history of use in Russia that extends back to the 1960's, a proven design methodology for ORSC cycle engines does not exist in the West. This lack of design expertise extends to the main chamber injector, a critical subcomponent that largely determines the engine performance and main chamber life. The goals of the effort described here are to establish an empirical knowledge base to provide a fundamental understanding of main chamber injectors and for verification of an injector design methodology for the ORSC cycle. The design of a baseline injector element, derived from information on Russian engines in the open literature, is presented. The baseline injector comprises a gaseous oxidizer core flow and an annular swirling fuel flow. Sets of equations describing the steady-state and the dynamic characteristics of the injector are presented; these equations, which form the basis of the design analysis methodology, will be verified in tests later this year. On-going cold flow studies, using nitrogen and water as simulants, are described which indicate highly atomized and symmetric sprays.
Long, Matthew R.↗
Cooled Ceramic Composite Panel Tested Successfully in Rocket Combustion Facility
Regeneratively cooled ceramic matrix composite (CMC) structures are being considered for use along the walls of the hot-flow paths of rocket-based or turbine-based combined-cycle propulsion systems. They offer the combined benefits of substantial weight savings, higher operating temperatures, and reduced coolant requirements in comparison to components designed with traditional metals. These cooled structures, which use the fuel as the coolant, require materials that can survive aggressive thermal, mechanical, acoustic, and aerodynamic loads while acting as heat exchangers, which can improve the efficiency of the engine. A team effort between the NASA Glenn Research Center, the NASA Marshall Space Flight Center, and various industrial partners has led to the design, development, and fabrication of several types of regeneratively cooled panels. The concepts for these panels range from ultra-lightweight designs that rely only on CMC tubes for coolant containment to more maintainable designs that incorporate metal coolant containment tubes to allow for the rapid assembly or disassembly of the heat exchanger. One of the cooled panels based on an all-CMC design was successfully tested in the rocket combustion facility at Glenn. Testing of the remaining four panels is underway.
Jaskowiak, Martha H.↗
Development of Advanced Stirling Radioisotope Generator for Space Exploration
Under the joint sponsorship of the Department of Energy and NASA, a radioisotope power system utilizing Stirling power conversion technology is being developed for potential future space missions. The higher conversion efficiency of the Stirling cycle compared with that of Radioisotope Thermoelectric Generators (RTGs) used in previous missions (Viking, Pioneer, Voyager, Galileo, Ulysses, Cassini, and New Horizons) offers the advantage of a four-fold reduction in PuO2 fuel, thereby saving cost and reducing radiation exposure to support personnel. With the advancement of state-of-the-art Stirling technology development under the NASA Research Announcement (NRA) project, the Stirling Radioisotope Generator program has evolved to incorporate the advanced Stirling convertor (ASC), provided by Sunpower, into an engineering unit. Due to the reduced envelope and lighter mass of the ASC compared to the previous Stirling convertor, the specific power of the flight generator is projected to increase from 3.5 to 7 We/kg, along with a 25 percent reduction in generator length. Modifications are being made to the ASC design to incorporate features for thermal, mechanical, and electrical integration with the engineering unit. These include the heat collector for hot end interface, cold-side flange for waste heat removal and structural attachment, and piston position sensor for ASC control and power factor correction. A single-fault tolerant, active power factor correction controller is used to synchronize the Stirling convertors, condition the electrical power from AC to DC, and to control the ASCs to maintain operation within temperature and piston stroke limits. Development activities at Sunpower and NASA Glenn Research Center (GRC) are also being conducted on the ASC to demonstrate the capability for long life, high reliability, and flight qualification needed for use in future missions.
Chan, Jack↗
Analytical and Experimental Performance of an Explosion-cycle Combustion Chamber for a Jet-propulsion Engine
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AIR FLOW - ENGINES, JET↗
Design tradeoff studies and sensitivity analysis, appendices B1 - B4
Documentation is presented for a program which separately computes fuel and energy consumption for the two modes of operation of a hybrid electric vehicle. The distribution of daily travel is specified as input data as well as the weights which the component driving cycles are given in each of the composite cycles. The possibility of weight reduction through the substitution of various materials is considered as well as the market potential for hybrid vehicles. Data relating to battery compartment weight distribution and vehicle handling analysis is tabulated.
Source record↗
Nonlinear heat transfer and structural analyses of SSME turbine blades
Three-dimensional nonlinear finite-element heat transfer and structural analyses were performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine (SSME). Directionally solidified (DS) MAR-M 246 material properties were considered for the analyses. Analytical conditions were based on a typical test stand engine cycle. Blade temperature and stress-strain histories were calculated using MARC finite-element computer code. The study was undertaken to assess the structural response of an SSME turbine blade and to gain greater understanding of blade damage mechanisms, convective cooling effects, and the thermal-mechanical effects.
Abdul-Aziz, A.↗
Rocketdyne Development of RBCC Engine for Low Cost Access to Space
Rocketdyne is pursuing the conceptual design and development of a Rocket Based Combined Cycle (RBCC) engine for booster and SSTO, advanced reusable space transportation ARTT systems under contract with NASA Marshall Space Flight Center. The Rocketdyne concept is fixed geometry integrated Rocket, Ram Scramjet which is Hydrogen fueled and uses Hydrogen regenerative cooling. Vision vehicle integration studies have determined that scramjet operation to Mach 12 has high payoff for low cost reusable space transportation. Rocketdyne is internally developing versions of the concept for other applications in high speed aircraft and missiles with Hydrocarbon fuel systems. Subscale engine ground testing is underway for all modes of operation from takeoff to Mach 8. High altitude Rocket only mode tests will be completed as part of the ground test program to validate high expansion ratio performance. A unique feature of the ground test series is the inclusion of dynamic trajectory simulation with real time Mach number, altitude, engine throttling, and RBCC mode changes in a specially modified freejet test facility at GASL. Preliminary cold flow Air Augmented Rocket mode test results and Short Combustor tests have met program goals and have been used to integrate all modes of operation in a single combustor design with a fixed geometry inlet for design confirmation tests. A water cooled subscale engine is being fabricated and installed for test beginning the last quarter of 1997.
Ortwerth, P.↗