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NASA NTRS2001

Rocket Engine Thrust Chamber Assembly

A thrust chamber assembly for liquid fueled rocket engines and the method of making it wherein a two-piece mandrel wrapped with a silica tape saturated with a phenolic resin, the tape extending along the mandrel and covering the combustion chamber portion of the mandrel to the throat portion. The phenolic in the tape is cured and the end of the wrap is machined. The remainder of the mandrel is wrapped with a third silica tape. The resin in the third tape is cured and the assembly is machined. The entire assembly is then wrapped with a tow of graphite fibers wetted with an epoxy resin and, after the epoxy resin is cured, the graphite is machined to final dimensions.

Cornelius, Charles S.↗
NASA NTRS2003

Unstructured LES of Reacting Multiphase Flows in Realistic Gas Turbine Combustors

As part of the Accelerated Strategic Computing Initiative (ASCI) program, an accurate and robust simulation tool is being developed to perform high-fidelity LES studies of multiphase, multiscale turbulent reacting flows in aircraft gas turbine combustor configurations using hybrid unstructured grids. In the combustor, pressurized gas from the upstream compressor is reacted with atomized liquid fuel to produce the combustion products that drive the downstream turbine. The Large Eddy Simulation (LES) approach is used to simulate the combustor because of its demonstrated superiority over RANS in predicting turbulent mixing, which is central to combustion. This paper summarizes the accomplishments of the combustor group over the past year, concentrating mainly on the two major milestones achieved this year: 1) Large scale simulation: A major rewrite and redesign of the flagship unstructured LES code has allowed the group to perform large eddy simulations of the complete combustor geometry (all 18 injectors) with over 100 million control volumes; 2) Multi-physics simulation in complex geometry: The first multi-physics simulations including fuel spray breakup, coalescence, evaporation, and combustion are now being performed in a single periodic sector (1/18th) of an actual Pratt & Whitney combustor geometry.

Ham, Frank↗
NASA NTRS2003

Recent Advances In Science Support For Isolated Droplet Combustion Experiments

In a joint program involving Prof. F.A. Williams of the University of California, San Diego and Dr. V. Nayagam of the National Center for Microgravity Research, the combustion characteristics of isolated liquid fuel droplets of n-heptane, n-decane, methanol, methanol-water, ethanol and ethanol-water having initial diameters between about 1 mm and 6 mm continues to be investigated. The objectives of the work are to improve fundamental knowledge of droplet combustion dynamics for pure fuels and fuel-water mixtures through microgravity experiments and theoretical analyses. The Princeton contributions support the engineering design, data analysis, and data interpretation requirements for the study of initially single component, spherically symmetric, isolated droplet combustion studies through experiments and numerical modeling. UCSD contributions are described in a companion communication in this conference. The Princeton effort also addresses the analyses of Fiber Supported Droplet Combustion (FSDC) experiments conducted with the above fuels and collaborative work with others who are investigating droplet combustion in the presence of steady convection. A thorough interpretation of droplet burning behavior for n-heptane and n-decane over a relatively wide range of conditions also involves the influences of sooting on the combustion behavior, and this particular aspect on isolated burning of droplets is under consideration in a collaborative program underway with Drexel University. This collaboration is addressed in another communication at this conference. The one-dimensional, time-dependent, numerical modeling approach that we have continued to evolve for analyzing isolated, quiescent droplet combustion data has been further applied to investigate several facets of isolated droplet burning of simple alcohols, n-heptane, and n-decane. Some of the new results are described below.

Dryer, F. L.↗
NASA NTRS2003

Modeling Candle Flame Behavior In Variable Gravity

The burning of a candle, as typical non-propagating diffusion flame, has been used by a number of researchers to study the effects of electric fields on flame, spontaneous flame oscillation and flickering phenomena, and flame extinction. In normal gravity, the heat released from combustion creates buoyant convection that draws oxygen into the flame. The strength of the buoyant flow depends on the gravitational level and it is expected that the flame shape, size and candle burning rate will vary with gravity. Experimentally, there exist studies of candle burning in enhanced gravity (i.e. higher than normal earth gravity, g(sub e)), and in microgravity in drop towers and space-based facilities. There are, however, no reported experimental data on candle burning in partial gravity (g < g(sub e)). In a previous numerical model of the candle flame, buoyant forces were neglected. The treatment of momentum equation was simplified using a potential flow approximation. Although the predicted flame characteristics agreed well with the experimental results, the model cannot be extended to cases with buoyant flows. In addition, because of the use of potential flow, no-slip boundary condition is not satisfied on the wick surface. So there is some uncertainty on the accuracy of the predicted flow field. In the present modeling effort, the full Navier-Stokes momentum equations with body force term is included. This enables us to study the effect of gravity on candle flames (with zero gravity as the limiting case). In addition, we consider radiation effects in more detail by solving the radiation transfer equation. In the previous study, flame radiation is treated as a simple loss term in the energy equation. Emphasis of the present model is on the gas-phase processes. Therefore, the detailed heat and mass transfer phenomena inside the porous wick are not treated. Instead, it is assumed that a thin layer of liquid fuel coated the entire wick surface during the burning process. This is the limiting case that the mass transfer process in the wick is much faster than the evaporation process at the wick surface.

Alsairafi, A.↗
NASA NTRS2004

Combustion Instability Analysis and the Effects of Drop Size on Acoustic Driving Rocket Flow

High frequency combustion instability, the most destructive kind, is generally solved on a per engine basis. The instability often is the result of compounding acoustic oscillations, usually from the propellant combustion itself. To counteract the instability the chamber geometry can be changed and/or the method of propellant injection can be altered. This experiment will alter the chamber dimensions slightly; using a cylindrical shape of constant diameter and the length will be varied from six to twelve inches in three-inch increments. The main flowfield will be the products of a high OF hydrogen/oxygen flow. The liquid fuel will be injected into this flowfield using a modulated injector. It will allow for varied droplet size, feed rate, spray pattern, and location for the mixture within the chamber. The response will be deduced from the chamber pressure oscillations.

Harper, Brent↗
NASA NTRS2004

Strategic Research to Enable NASA's Exploration Missions Conference and Workshop: Poster Session

Reports are presented from volume 2 of the conference titled Strategic Research to Enable NASA's Exploration Missions, poster session. Topics included spacecraft fire suppression and fire extinguishing agents,materials flammability, various topics on the effects of microgravity including crystal growth, fluid mechanics, electric particulate suspension, melting and solidification, bubble formation, the sloshing of liquid fuels, biological studies, separation of carbon dioxide and carbon monoxide for Mars ISRU.

Nahra, Henry↗
NASA NTRS1957

Heat of Combustion of the Product Formed by the Reaction of Acetylene and Diborane (LFPL-CZ-3)

The heat of combustion of the product formed by the reaction acetylene and diborane was found to be 20,100 +/- 100 Btu per pound for the reaction of liquid fuel to gaseous carbon dioxide, gaseous water, and solid boric oxide. The measurements were made in a Parr oxygen-bomb calorimeter, and chemical analyses both of the sample and of the combustion products indicated combustion in the bomb calorimeter to have been 97 percent complete. The estimated net heat of combustion for complete combustion would therefore be 20,700 +/- 100 Btu per pound.

Allen, Harrison, Jr.↗
NASA NTRS1957

Heat of Combustion of the Product Formed by the Reaction of Acetylene, Ethylene, and Diborane

The net heat of combustion of the product formed by the reaction of diborane with a mixture of acetylene and ethylene was found to be 20,440 +/- 150 Btu per pound for the reaction of liquid fuel to gaseous carbon dioxide, gaseous water, and solid boric oxide. The measurements were made in a Parr oxygen-bomb calorimeter, and the combustion was believed to be 98 percent complete. The estimated net-heat of combustion for complete combustion would therefore be 20,850 +/- 150 Btu per pound.

Tannenbaum, Stanley↗
NASA NTRS2005

In-situ Production of High Density Polyethylene and Other Useful Materials on Mars

This paper describes a revolutionary materials structure and power storage concept based on the in-situ production of abiotic carbon 4 compounds. One of the largest single mass penalties required to support the human exploration of Mars is the surface habitat. This proposal will use physical chemical technologies to produce high density polyethylene (HDPE) inflatable structures and construction materials from Mars atmospheric CO2. The formation of polyethylene from Mars CO2 is based on the use of the Sabatier and modified Fischer Tropsch reactions. The proposed system will fully integrate with existing in-situ propellant production concepts. The technology will also be capable of supplementing human caloric requirements, providing solid and liquid fuels for energy storage, and providing significant reduction in mission risk. The NASA Mars Reference Mission Definition Team estimated that a conventional Mars surface habitat structure would weigh 10 tonnes. It is estimated that this technology could reduce this mass by 80%. This reduction in mass will significantly contribute to the reduction in total mission cost need to make a Mars mission a reality. In addition the potential reduction of risk provided by the ability to produce C4 and potentially higher carbon based materials in-situ on Mars is significant. Food, fuel, and shelter are only three of many requirements that would be impacted by this research.

Flynn, Michael↗
NASA NTRS1995

Ceramic Composites Used in High-Speed Turbines for Rocket Engines

Ceramic matrix composite (CMC) technology offers many benefits for liquid-fueled rocket engines. Analyses show that components made from fiber-reinforced ceramic matrix composites (FRCMC's) offer the opportunity for revolutionary gains in turbomachinery performance. In addition, they offer reduced weight and the potential for longer life and lower operating costs. A NASA-sponsored turbopump development effort, conducted at Rocketdyne with parallel material characterization at the NASA Lewis Research Center, confirmed the potential to use FRCMC's for complex turbomachinery components.

Source record↗
NASA NTRS2000

Engine-Scale Combustor Rig Designed, Fabricated, and Tested for Combustion Instability Control Research

Low-emission combustor designs are prone to combustor instabilities. Because active control of these instabilities may allow future combustors to meet both stringent emissions and performance requirements, an experimental combustor rig was developed for investigating methods of actively suppressing combustion instabilities. The experimental rig has features similar to a real engine combustor and exhibits instabilities representative of those in aircraft gas turbine engines. Experimental testing in the spring of 1999 demonstrated that the rig can be tuned to closely represent an instability observed in engine tests. Future plans are to develop and demonstrate combustion instability control using this experimental combustor rig. The NASA Glenn Research Center at Lewis Field is leading the Combustion Instability Control program to investigate methods for actively suppressing combustion instabilities. Under this program, a single-nozzle, liquid-fueled research combustor rig was designed, fabricated, and tested. The rig has many of the complexities of a real engine combustor, including an actual fuel nozzle and swirler, dilution cooling, and an effusion-cooled liner. Prior to designing the experimental rig, a survey of aircraft engine combustion instability experience identified an instability observed in a prototype engine as a suitable candidate for replication. The frequency of the instability was 525 Hz, with an amplitude of approximately 1.5-psi peak-to-peak at a burner pressure of 200 psia. The single-nozzle experimental combustor rig was designed to preserve subcomponent lengths, cross sectional area distribution, flow distribution, pressure-drop distribution, temperature distribution, and other factors previously found to be determinants of burner acoustic frequencies, mode shapes, gain, and damping. Analytical models were used to predict the acoustic resonances of both the engine combustor and proposed experiment. The analysis confirmed that the test rig configuration and engine configuration had similar longitudinal acoustic characteristics, increasing the likelihood that the engine instability would be replicated in the rig. Parametric analytical studies were performed to understand the influence of geometry and condition variations and to establish a combustion test plan. Cold-flow experiments verified that the design values of area and flow distributions were obtained. Combustion test results established the existence of a longitudinal combustion instability in the 500-Hz range with a measured amplitude approximating that observed in the engine. Modifications to the rig configuration during testing also showed the potential for injector independence. The research combustor rig was developed in partnership with Pratt & Whitney of West Palm Beach, Florida, and United Technologies Research Center of East Hartford, Connecticut. Experimental testing of the combustor rig took place at United Technologies Research Center.

DeLaat, John C.↗
NASA NTRS2004

Adaptive Controls Method Demonstrated for the Active Suppression of Instabilities in Engine Combustors

An adaptive feedback control method was demonstrated that suppresses thermoacoustic instabilities in a liquid-fueled combustor of a type used in aircraft engines. Extensive research has been done to develop lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle to reduce the environmental impact of aerospace propulsion systems. However, these lean-burning combustors are susceptible to thermoacoustic instabilities (high-frequency pressure waves), which can fatigue combustor components and even the downstream turbine blades. This can significantly decrease the safe operating lives of the combustor and turbine. Thus, suppressing the thermoacoustic combustor instabilities is an enabling technology for lean, low-emissions combustors under NASA's Propulsion and Power Program. This control methodology has been developed and tested in a partnership of the NASA Glenn Research Center, Pratt & Whitney, United Technologies Research Center, and the Georgia Institute of Technology. Initial combustor rig testing of the controls algorithm was completed during 2002. Subsequently, the test results were analyzed and improvements to the method were incorporated in 2003, which culminated in the final status of this controls algorithm. This control methodology is based on adaptive phase shifting. The combustor pressure oscillations are sensed and phase shifted, and a high-frequency fuel valve is actuated to put pressure oscillations into the combustor to cancel pressure oscillations produced by the instability.

Kopasakis, George↗
NASA NTRS2002

High-Pressure Gaseous Burner (HPGB) Facility Completed for Quantitative Laser Diagnostics Calibration

A gas-fueled high-pressure combustion facility with optical access, which was developed over the last 2 years, has just been completed. The High Pressure Gaseous Burner (HPGB) rig at the NASA Glenn Research Center can operate at sustained pressures up to 60 atm with a variety of gaseous fuels and liquid jet fuel. The facility is unique as it is the only continuous-flow, hydrogen-capable, 60-atm rig in the world with optical access. It will provide researchers with new insights into flame conditions that simulate the environment inside the ultra-high-pressure-ratio combustion chambers of tomorrow's advanced aircraft engines. The facility provides optical access to the flame zone, enabling the calibration of nonintrusive optical diagnostics to measure chemical species and temperature. The data from the HPGB rig enables the validation of numerical codes that simulate gas turbine combustors, such as the National Combustor Code (NCC). The validation of such numerical codes is often best achieved with nonintrusive optical diagnostic techniques that meet these goals: information-rich (multispecies) and quantitative while providing good spatial and time resolution. Achieving these goals is a challenge for most nonintrusive optical diagnostic techniques. Raman scattering is a technique that meets these challenges. Raman scattering occurs when intense laser light interacts with molecules to radiate light at a shifted wavelength (known as the Raman shift). This shift in wavelength is unique to each chemical species and provides a "fingerprint" of the different species present. The facility will first be used to gather a comprehensive data base of laser Raman spectra at high pressures. These calibration data will then be used to quantify future laser Raman measurements of chemical species concentration and temperature in this facility and other facilities that use Raman scattering.

Nguyen, Quang-Viet↗
NASA NTRS2005

Reliability Improvements in Liquid Rocket Engine Instrumentation

Instrumentation hardware is often the weak link in advanced liquid fueled propulsion systems. The development of the Space Shuttle Main Engine (SSME) was no exception. By sheer necessity, a reusable, high energy, low weight engine system often relegates the instrumentation hardware to the backseat in the critical hardware development process. This produces less than optimum hardware constraints; including size, location, mounting, redundancy, and signal conditioning. This can negatively affect the development effort and ultimately the system reliability. The challenge was clear, however, the outcome was less certain. Unfortunately, the SSME hardware development culminated in series of measurement failures, most significant of which was the premature engine shutdown during the launch of STS-51F on July 29, 1985. The Return to Flight activities following the Challenger disaster redoubled our efforts to eliminate, once and for all, sensor malfunctions as the determining factor in overall engine reliability. This paper describes each phase of this effort in detail and includes discussion of the tasks related to improving measurement reliability.

Hill, A.↗
NASA NTRS2002

Combustion of Interacting Droplet Arrays Being Studied

The combustion of liquid fuels is a major source of energy in the world today, and the majority of these fuels are burned in the form of a spray. This droplet combustion project at the NASA Glenn Research Center has the overall goal of providing a better understanding of spray combustion by extending existing studies of single droplets to a regime where droplet interactions are important (as occurs in a practical spray). The Combustion of Interacting Droplet Arrays is a collaborative effort between Glenn and the National Center for Microgravity Research. The group at Glenn also collaborates with scientists at the National Institute of Advanced Industrial Science and Technology in Hokkaido, Japan. The project is studying the combustion of a small number of droplets suspended on small quartz fibers in a 0.1-atm combustion chamber. Data consist primarily of video images of the flames and droplets. The tests are being conducted in Glenn's reduced-gravity facilities (2.2-sec and 5.2-sec drop towers) and in the Japan Microgravity Center's 10-sec drop tower (JAMIC).

Dietrich, Daniel L.↗
NASA NTRS2003

High-Pressure Gaseous Burner (HPGB) Facility Became Operational

A gas-fueled high-pressure combustion facility with optical access, developed over the last 3 years, is now collecting research data in a production mode. The High-Pressure Gaseous Burner (HPGB) rig at the NASA Glenn Research Center can operate at sustained pressures up to 60 atm with a variety of gaseous fuels and liquid jet fuel. The facility is unique because it is the only continuous-flow, hydrogen-capable 60-atm rig in the world with optical access. It will provide researchers with new insights into flame conditions that simulate the environment inside the ultra-high-pressure-ratio combustion chambers of tomorrow s advanced aircraft engines. The facility provides optical access to the flame zone through four fused-silica optical windows, enabling the calibration of nonintrusive optical diagnostics to measure chemical species and temperature. The data from the HPGB rig enable the validation of numerical codes that simulate gas turbine combustors.

Nguyen, Quang-Viet↗
NASA NTRS2005

Control of Combustion-Instabilities Through Various Passive Devices

It is well known that under some operating conditions, rocket engines (using solid or liquid fuels) exhibit unstable modes of operation that can lead to engine malfunction and shutdown. The sources of these instabilities are diverse and are dependent on fuel, chamber geometry and various upstream sources such as pumps, valves and injection mechanism. It is believed that combustion-acoustic instabilities occur when the acoustic energy increase due to the unsteady heat release of the flame is greater than the losses of acoustic energy from the system [1, 2]. Giammar and Putnam [3] performed a comprehensive study of noise generated by gasfired industrial burners and made several key observations; flow noise was sometimes more intense than combustion roar, which tended to have a characteristic frequency spectrum. Turbulence was amplified by the flame. The noise power varied directly with combustion intensity and also with the product of pressure drop and heat release rate. Karchmer [4] correlated the noise emitted from a turbofan jet engine with that in the combustion chamber. This is important, since it quantified how much of the noise from an engine originates in the combustor. A physical interpretation of the interchange of energy between sound waves and unsteady heat release rates was given by Rayleigh [5] for inviscid, linear perturbations. Bloxidge et al [6] extended Rayleigh s criterion to describe the interaction of unsteady combustion with one-dimensional acoustic waves in a duct. Solutions to the mass, momentum and energy conservation equations in the pre- and post-flame zones were matched by making several assumptions about the combustion process. They concluded that changes in boundary conditions affect the energy balance of acoustic waves in the combustor. Abouseif et al [7] also solved the one-dimensional flow equations, but they used a onestep reaction to evaluate the unsteady heat release rate by relating it to temperature and velocity perturbations. Their analysis showed that oscillations arise from coupling between entropy waves produced at the flame and pressure waves originating from the nozzle. Yang and Culick [8] assumed a thin flame sheet, which is distorted by velocity and pressure oscillations. Conservation equations were expressed in integral form and solutions for the acoustic wave equations and complex frequencies were obtained. The imaginary part of the frequency indicated stability regions of the flame. Activation energy asymptotics together with a one-step reaction were used by McIntosh [9] to study the effects of acoustic forcing and feedback on unsteady, one-dimensional flames. He found that the flame stability was altered by the upstream acoustic feedback. Shyy et al [10] used a high-accuracy TVD scheme to simulate unsteady, one-dimensional longitudinal, combustion instabilities. However, numerical diffusion was not completely eliminated. Recently, Prasad [11] investigated numerically the interactions of pressure perturbations with premixed flames. He used complex chemistry to study responses of pressure perturbations in one-dimensional combustors. His results indicated that reflected and transmitted waves differed significantly from incident waves.

Frendi, Kader↗
NASA NTRS2005

Innovative Adaptive Control Method Demonstrated for Active Suppression of Instabilities in Engine Combustors

This year, an improved adaptive-feedback control method was demonstrated that suppresses thermoacoustic instabilities in a liquid-fueled combustor of a type used in aircraft engines. Extensive research has been done to develop lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle to reduce the environmental impact of aerospace propulsion systems. However, these lean-burning combustors are susceptible to thermoacoustic instabilities (high-frequency pressure waves), which can fatigue combustor components and even downstream turbine blades. This can significantly decrease the safe operating life of the combustor and turbine. Thus, suppressing the thermoacoustic combustor instabilities is an enabling technology for meeting the low-emission goals of the NASA Ultra-Efficient Engine Technology (UEET) Project.

Kopasakis, George↗