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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 847 records · Page 47

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NASA NTRS1984

NASA Orbit Transfer Rocket Engine Technology Program

The advanced expander cycle engine with a 15,000 lb thrust level and a 6:1 mixture ratio and optimized performance was used as the baseline for a design study of the hydrogen/oxgyen propulsion system for the orbit transfer vehicle. The critical components of this engine are the thrust chamber, the turbomachinery, the extendible nozzle system, and the engine throttling system. Turbomachinery technology is examined for gears, bearing, seals, and rapid solidification rate turbopump shafts. Continuous throttling concepts are discussed. Components of the OTV engine described include the thrust chamber/nozzle assembly design, nozzles, the hydrogen regenerator, the gaseous oxygen heat exchanger, turbopumps, and the engine control valves.

Source record↗

NASA NTRS1984

High-pressure hydrogen testing of single crystal superalloys for advanced rocket engine turbopump turbine blades

A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.

Alter, W. S.↗

NASA NTRS1984

Analysis of large solid propellant rocket engine exhaust plumes using the direct simulation Monte Carlo method

A new solution procedure has been developed to analyze the flowfield properties in the vicinity of the Inertial Upper Stage/Spacecraft during the 1st stage (SRMI) burn. Continuum methods are used to compute the nozzle flow and the exhaust plume flowfield as far as the boundary where the breakdown of translational equilibrium leaves these methods invalid. The Direct Simulation Monte Carlo (DSMC) method is applied everywhere beyond this breakdown boundary. The flowfield distributions of density, velocity, temperature, relative abundance, surface flux density, and pressure are discussed for each species for 2 sets of boundary conditions: vacuum and freestream. The interaction of the exhaust plume and the freestream with the spacecraft and the 2-stream direct interaction are discussed. The results show that the low density, high velocity, counter flowing free-stream substantially modifies the flowfield properties and the flux density incident on the spacecraft. A freestream bow shock is observed in the data, located forward of the high density region of the exhaust plume into which the freestream gas does not penetrate. The total flux density incident on the spacecraft, integrated over the SRM1 burn interval is estimated to be of the order of 10 to the 22nd per sq m (about 1000 atomic layers).

Hueser, J. E.↗

NASA NTRS1982

A technology data base for the design of 500 to 5000-lb thrust class liquid rocket engines utilizing hydrogen and oxygen as propellants

This paper presents an overview of the results of experimental evaluations of candidate designs for igniters, injectors, and propellant-cooled thrust chambers applicable to restartable high-performance, high-reliability upper-stage engines and to pulsing-type reaction control engines (RCE). Injection element types best suited for liquid, gas, and liquid/gas phase propellant supply are identified. The resulting interactions between element type, combustion efficiency, and chamber wall heating are compared. The distinction between thrust chamber design requirements for upper stage vs RCE applications as measured by cycle life requirements is translated into design configurations consisting of all-film-cooled, all-regeneratively-cooled, and composites of the two cooling approaches. The validity of the design approaches is confirmed by data from engine durability testing involving over 90,000 starts and 9,000 thermal cycles on RCE-type designs and multiple long-duration burns (up to 2,000 sec) on regeneratively cooled upper-stage designs.

Schoenman, L.↗

NASA NTRS1984

Development of a three-phrase combustion code for modeling liquid rocket engines

A two-dimensional/axisymmetric program for the simulation of three-phase reactive flows is presented. The three phases are: a multiple-species gaseous phase, a single-species liquid phase, and a particulate droplet phase. The liquid and gaseous phases are described with continuous Eulerian equations, while the droplets are described in a discrete Lagrangian fashion. The three phases are fully coupled together. An atomization model, a multireaction chemical kinetics model, and a subgrid scale turbulence model completes the description of a general liquid/gas bipropellant combustion process. The code development criteria and qualitative features are highlighted.

Liang, P. Y.↗

NASA NTRS1985

High-pressure hydrogen testing of single crystal superalloys for advanced rocket engine turbopump turbine blades

Parr, R. A.↗

NASA NTRS1985

Advanced rocket engine cryogenic turbopump bearing thermal model

A lumped node thermal model was developed representing the Space Shuttle Main Engine (SSME) liquid oxygen (LOX) turbopump turbine end bearings operating in a cryogenically cooled bearing tester. Bearing elements, shaft, carrier, housing, cryogen flow characteristics, friction heat, and fluid viscous energy are included in the model. Heat transfer characteristics for the regimes of forced convection boiling are modeled for liquid oxygen (LOX) and liquid nitrogen (LN2). Large temperature differences between the cryogenic fluid and baring contact surfaces require detailed nodal representation in these areas. Internal loads and friction heat are affected by temperature dependent operating clearances requiring iterations between bearing thermal and mechanical models. Analyses indicate a thermal-mechanical coupling resulting in reduced operating clearances, increased loading and heating which can contribute to premature bearing failure. Contact surfaces operate at temperatures above local saturation resulting in vapor rather than liquid in the contacts, precluding possible liquid film lubrication. Elevated temperatures can reduce lubrication, increase friction, and reduce surface hardness supporting a surface failure mode rather than subsurface fatigue.

Cody, J. C.↗

NASA NTRS1985

Powder metallurgy bearings for advanced rocket engines

Traditional ingot metallurgy was pushed to the limit for many demanding applications including antifriction bearings. New systems require corrosion resistance, better fatigue resistance, and higher toughness. With conventional processing, increasing the alloying level to achieve corrosion resistance results in a decrease in other properties such as toughness. Advanced powder metallurgy affords a viable solution to this problem. During powder manufacture, the individual particle solidifies very rapidly; as a consequence, the primary carbides are very small and uniformly distributed. When properly consolidated, this uniform structure is preserved while generating a fully dense product. Element tests including rolling contact fatigue, hot hardness, wear, fracture toughness, and corrosion resistance are underway on eleven candidate P/M bearing alloys and results are compared with those for wrought 440C steel, the current SSME bearing material. Several materials which offer the promise of a significant improvement in performance were identified.

Fleck, J. N.↗

NASA NTRS1985

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with attendant reductions in maintenance costs and turnaround times can be achieved with an engine condition monitoring system (CMS). The CMS provides real time health status of critical engine components, without disassembly, through component monitoring with advanced sensor technologies. Three technologies were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiber optic deflectometer (bearings), and the fiber optic pyrometer (blades). Signal processing algorithms were evaluated and ranked for their utility in providing useful component health data to unskilled maintenance personnel. Design modifications to current configuration Space Shuttle Main Engine (SSME) high pressure turbopumps and the MK48-F turbopump were developed to incorporate the sensors.

Hampson, M. E.↗

NASA NTRS1984

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with reductions in maintenance costs and turn-around times can be achieved with an engine condition monitoring systems (CMS). The CMS provides health status of critical engine components, without disassembly, through monitoring with advanced sensors. Engine failure reports over 35 years were categorized into 20 different modes of failure. Rotor bearings and turbine blades were determined to be the most critical in limiting turbopump life. Measurement technologies were matched to each of the failure modes identified. Three were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiberoptic deflectometer (bearings), and the fiberoptic pyrometer (blades). Signal processing algorithms were evaluated for their ability to provide useful health data to maintenance personnel. Design modifications to the Space Shuttle Main Engine (SSME) high pressure turbopumps were developed to incorporate the sensors. Laboratory test fixtures have been designed for monitoring the rotor bearings and turbine blades in simulated turbopump operating conditions.

Hampson, M. E.↗

NASA NTRS1986

Orbit Transfer Rocket Engine Technology Program: Advanced engine study, task D.1/D.3

Concepts for space maintainability of OTV engines were examined. An engine design was developed which was driven by space maintenance requirements and by a failure mode and effects (FME) analysis. Modularity within the engine was shown to offer cost benefits and improved space maintenance capabilities. Space operable disconnects were conceptualized for both engine change-out and for module replacement. Through FME mitigation the modules were conceptualized to contain the least reliable and most often replaced engine components. A preliminary space maintenance plan was developed around a controls and condition monitoring system using advanced sensors, controls, and condition monitoring concepts. A complete engine layout was prepared satisfying current vehicle requirements and utilizing projected component advanced technologies. A technology plan for developing the required technology was assembled.

Martinez, A.↗

NASA NTRS1986

Small centrifugal pumps for low-thrust rocket engines

Six small, low specific speed centrifugal pump configurations were designed, fabricated, and tested. The configurations included shrouded, and 25 and 100% admission open face impellers with 2 inch tip diameters; 25, 50, and 100% emission vaned diffusers; and volutes with conical exits. Impeller tip widths varied from 0.030 inch to 0.052 inch. Design specific speeds (N sub s = RPM*GPM**0.5.FT**0.75) were 430 (four configurations) and 215 (two configurations). The six configurations were tested with water as the pumped fluid. Noncavitating performance results are presented for the design speed of 24,500 rpm over a flowrate range from 1 to 6 gpm for the N sub s = 430 configurations and test speeds up to 29,000 rpm over a flowrate range from 0.3 to 1.2 gpm for the N sub s = 215 configurations. Cavitating performance results are presented over a flowrate range from 60 to 120% of design flow. Fabrication of the small pump conponents is also discussed.

Furst, R. B.↗

NASA NTRS1986

Effects of geometry and materials on low cycle fatigue life of turbine blades in LOX/hydrogen rocket engines

This paper presents the results of an advanced turbine blade test program aimed at improving turbine blade low cycle fatigue (LCF) life. A total of 21 blades were tested in a blade thermal tester. The blades were made of MAR-M-246(Hf)DS and PWA-1480SC in six different geometries. The test results show that the PWA-1480SC material improved life by a factor of 1.7 to 3.0 over the current MAR-M-246(Hf)DS. The geometry changes yielded life improvements as high as 20 times the baseline blade made of PWA-1480SC and 34 times the baseline MAR-M-246DS blade.

Ryan, R. M.↗

NASA NTRS1987

Combustion stability analysis of preburners in liquid propellant rocket engines during shutdown

A linearized one-dimensional lumped-parameter model capable of predicting the occurrence of the low frequency combustion instability (chugging) experienced during preburner shutdown in the Space Shuttle Main Engines is discussed, and predictions are compared with NASA experimental results. Results from a parametric study of parameters including chamber pressure, fuel and oxygen temperatures, and the effective bulk modulus of the liquid oxidizer suggest that chugging is probably affected by conditions at shutdown through the fuel and oxidizer temperatures. It is suggested that chugging is initiated when the fuel, oxidizer, and helium temperature and flow rates pass into an unstable region, and that chugging may be terminated by decaying pressures.

Lim, Kair-Chuan↗

NASA NTRS1987

Development of a generic combustion stability code for liquid propellant rocket engines

The mathematical framework for a combustion stability analysis code is outlined. The goal for the code is to be general enough in problem treatment so that its validity and accuracy extend over a wide range of problem applications and that it lends the convenience for any future model improvement if necessary. An approach for modeling the combustion dynamics is devised to meet both requirements. An open-loop numerical procedure is also developed to mechanistically model various combustion processes for determining the stability parameters.

Fang, J. J.↗

NASA NTRS1987

A computer program for performance prediction of tripropellant rocket engines with tangential slot injection

For the development of a Heavy Lift Launch Vehicle (HLLV) several engines with different operating cycles and using LOX/Hydrocarbon propellants are presently being examined. Some concepts utilize hydrogen for thrust chamber wall cooling followed by a gas generator turbine drive cycle with subsequent dumping of H2/O2 combustion products into the nozzle downstream of the throat. In the Space Transportation Booster Engine (STBE) selection process the specific impulse will be one of the optimization criteria; however, the current performance prediction programs do not have the capability to include a third propellant in this process, nor to account for the effect of dumping the gas-generator product tangentially inside the nozzle. The purpose is to describe a computer program for accurately predicting the performance of such an engine. The code consists of two modules; one for the inviscid performance, and the other for the viscous loss. For the first module, the two-dimensional kinetics program (TDK) was modified to account for tripropellant chemistry, and for the effect of tangential slot injection. For the viscous loss, the Mass Addition Boundary Layer program (MABL) was modified to include the effects of the boundary layer-shear layer interaction, and tripropellant chemistry. Calculations were made for a real engine and compared with available data.

Dang, Anthony↗

NASA NTRS1988

Evaluation and Improvement of Liquid Propellant Rocket Chugging Analysis Techniques. Part 2: a Study of Low Frequency Combustion Instability in Rocket Engine Preburners Using a Heterogeneous Stirred Tank Reactor Model

During the shutdown of the space shuttle main engine, oxygen flow is shut off from the fuel preburner and helium is used to push the residual oxygen into the combustion chamber. During this process a low frequency combustion instability, or chug, occurs. This chug has resulted in damage to the engine's augmented spark igniter due to backflow of the contents of the preburner combustion chamber into the oxidizer feed system. To determine possible causes and fixes for the chug, the fuel preburner was modeled as a heterogeneous stirred tank combustion chamber, a variable mass flow rate oxidizer feed system, a constant mass flow rate fuel feed system and an exit turbine. Within the combustion chamber gases were assumed perfectly mixed. To account for liquid in the combustion chamber, a uniform droplet distribution was assumed to exist in the chamber, with mean droplet diameter determined from an empirical relation. A computer program was written to integrate the resulting differential equations. Because chamber contents were assumed perfectly mixed, the fuel preburner model erroneously predicted that combustion would not take place during shutdown. The combustion rate model was modified to assume that all liquid oxygen that vaporized instantaneously combusted with fuel. Using this combustion model, the effect of engine parameters on chamber pressure oscillations during the SSME shutdown was calculated.

Bartrand, Timothy A.↗

NASA NTRS1988

3-D thermal analysis using finite difference technique with finite element model for improved design of components of rocket engine turbomachines for Space Shuttle Main Engine SSME

Three-dimensional finite element models were generated and transferred into three-dimensional finite difference models to perform transient thermal analyses for the SSME high pressure fuel turbopump's first stage nozzles and rotor blades. STANCOOL was chosen to calculate the heat transfer characteristics (HTCs) around the airfoils, and endwall effects were included at the intersections of the airfoils and platforms for the steady-state boundary conditions. Free and forced convection due to rotation effects were also considered in hollow cores. Transient HTCs were calculated by taking ratios of the steady-state values based on the flow rates and fluid properties calculated at each time slice. Results are presented for both transient plots and three-dimensional color contour isotherm plots; they were also converted into universal files to be used for FEM stress analyses.

Sohn, Kiho D.↗