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At least 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Adaptive computational methods for SSME internal flow analysis

Adaptive finite element methods for the analysis of classes of problems in compressible and incompressible flow of interest in SSME (space shuttle main engine) analysis and design are described. The general objective of the adaptive methods is to improve and to quantify the quality of numerical solutions to the governing partial differential equations of fluid dynamics in two-dimensional cases. There are several different families of adaptive schemes that can be used to improve the quality of solutions in complex flow simulations. Among these are: (1) r-methods (node-redistribution or moving mesh methods) in which a fixed number of nodal points is allowed to migrate to points in the mesh where high error is detected; (2) h-methods, in which the mesh size h is automatically refined to reduce local error; and (3) p-methods, in which the local degree p of the finite element approximation is increased to reduce local error. Two of the three basic techniques have been studied in this project: an r-method for steady Euler equations in two dimensions and a p-method for transient, laminar, viscous incompressible flow. Numerical results are presented. A brief introduction to residual methods of a-posterior error estimation is also given and some pertinent conclusions of the study are listed.

Oden, J. T.↗
NASA NTRS1986

Viscous flow computations for elliptical two-duct version of the SSME hot gas manifold

The objective of the effort was to numerically simulate viscous subsonic flow in a proposed elliptical two-duct version of the fuel side Hot Gas Manifold (HGM) for the Space Shuttle Main Engine (SSME). The numerical results were to complement both water flow and air flow experiments in the two-duct geometry performed at NASA-MSFC and Rocketdyne. The three-dimensional character of the HGM consists of two essentially different geometries. The first part of the construction is a concentric shell duct structure which channels the gases from a turbine exit into the second part comprised of two cylindrically shaped transfer ducts. The initial concentric shell portion can be further subdivided into a turnaround section and a bowl section. The turnaround duct (TAD) changes the direction of the mean flow by 180 degress from a smaller radius to a larger radius duct which discharges into the bowl. The cylindrical transfer ducts are attached to the bowl on one side thus providing a plane of symmetry midway between the two. Centerline flow distance from the TAD inlet to the transfer duct exit is approximately two feet. Details of the approach used to numerically simulate laminar or turbulent flow in the HGM geometry are presented. Computational results are presented and discussed.

Roger, R. P.↗
NASA NTRS1985

Computer-aided selection of materials for cryogenic turbopump bearings

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high-pressure-oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life has been experienced. The objective of this current program is to identify bearing materials and/or materials processing techniques offering significant potential for extending HPOTP bearing performance life. A thermomechanical analysis of the HPOTP shaft/bearing system was performed with the SHABERTH (SHaft-BEaring-THermal) computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures, and circumferential stress in the inner rings were quantified as functions of radial load, thrust load, and ball-race contact friction. The analysis results were used to formulate criteria that are being used for the selection of special materials for future turbopump bearings.

Maurer, R. E.↗
NASA NTRS1985

An analysis of pump cavitation damage

The cavitation assessment for the space shuttle main engine high pressure oxidizer turbopump is documented. A model of the flow through the pump was developed. Initially, a computational procedure was used to analyze the flow through the inlet casing including the prediction of wakes downstream of the casing vanes. From these flow calculations, cavitation patterns on the inducer blades were approximated and the damage rate estimated. The model correlates the heavy damage on the housing and over the inducer with unsteady blade surface cavitation. The unsteady blade surface cavitation is due to the large incidence changes caused by the wakes of the upstream vanes. Very high cavitation damage rates are associated with this type of cavitation. Design recommendations for reducing the unsteady cavitation include removing the set of vanes closest to the inducer and modifying the remaining vanes.

Brophy, M. C.↗
NASA NTRS1985

Operational life improvement of SSME high-pressure turbopumps

The current Space Shuttle Main Engine (SSME) Phase I engine demonstrated excellent flight performance but showed limited operational life of the high-pressure fuel turbopumps (HPFTP). Design improvements, supporting analyses, and test results of the SSME Phase II development program are presented. The HPFTP improvements include reduction of turbine operating temperature by 110 to 130 R by reconstructing the seals and the flow contours; modifications of the first- and second-stage turbine blades by recontouring the shank, shotpeening the shank surface, and applying a multilayered, plasma-spray coating to the shank on the downstream side to reduce the effect of the disk coolant; and reduction of the tendency for thermal cracks in the turbine by changing weld configuration to avoid the concentration of stresses in local areas. The high-pressure oxidizer turbopump has been also modified to improve bearing life and to eliminate subsynchronous whirl.

Hale, J. R.↗
NASA NTRS1986

Wind tunnel test evaluation of a Shuttle derived launch system

The Shuttle Derived Vehicle (SDV) is a proposed unmanned launch system configured using Shuttle elements. The SDV incorporates two solid rocket boosters, an external tank and three Space Shuttle main engines identical to those used in the present Space Transportation System. Two new elements, a recoverable propulsion/avionics module housing the main engines and an expendable payload module, complete the SDV configuration. This paper describes the activities and results of wind tunnel tests conducted to validate the aerodynamic and controllability characteristics of SDV configurations. The configuration variables consisted of the payload module diameter, length and nose shape. The tests were conducted in the NASA/Marshall Space Flight Center 14 inch trisonic wind tunnel. Aerodynamic force and moment data were obtained over a Mach number range of 0.6 to 4.96. The attack and sideslip angles were varied + or - 8.0 deg. Forces and moments were measured by a sting-supported six component strain gage balance.

Tewell, J. R.↗
NASA NTRS1986

STS performance enhancements for a heads up ascent design

A method of increasing the STS (space transportation system) lift capability by flying the SSV (Space Shuttle vehicle) in a heads up attitude during the first stage atmospheric flight as opposed to the current heads down attitude is presented. The paper reveals that the STS lift capability and SRM (solid rocket motor) burnrate definition are sensitive to the magnitude and direction of normal aerodynamic force acting on the SSV during atmospheric ascent. The STS operational trajectory design angle of attack will permit increases in SRM burnrate definition and STS lift capability for the proposed heads up ascent when compared to the current heads down ascent. For a heads up ascent the SRM burnrate can be increased 7 percent with a corresponding 4000 lb increase in STS lift capability. A comparison of the heads up and heads down ascent reveals similar performance trades for changes in trajectory shaping parameters and SRM and SSME (Space Shuttle main engine) performance characteristics.

Millard, S. W.↗
NASA NTRS1986

Numerical analysis of SSME preburner injector atomization and combustion processes

The coaxial spray injection and combustion flowfields of a Space Shuttle Main Engine preburner injector element have been analyzed using a three-phase numerical code. The processes of atomization, evaporation, secondary droplet breakup, and multispecies chemistry, as well as turbulent diffusion, are included. The model produced realistic pictures of the complex internal flowfield, including liquid jet length, spray shape, flame-zone size and characteristics, and predicted temperatures that seem to be in agreement with test data envelopes. It predicted an external group combustion type of flame. Salient combustion and mixing features are discussed and sources of uncertainty are pointed out for future studies.

Liang, P. Y.↗
NASA NTRS1986

Thrust improvement with ablative insert nozzle extension

Aspects are examined of an investigation by the Marshall Space Flight Center into the conceptual feasibility of increasing the thrust performance of the Space Shuttle Main Engine (SSME) by using a conical nozzle extension fitted with an ablative insert in order to achieve a low-cost, near-term gain in payload. The ablating insert would provide a controlled increase in nozzle expansion ratio during launch and early climbout (first 30-60 seconds) so as to reduce thrust loss from nozzle over-expansion in the lower atmosphere. Summaries are given of JPL studies in the area of: defining the near-wall flow environment in the extended nozzle insert region; selecting potential insert materials; conceptualizing an extension/insert geometrical configuration; and identifying future experimental efforts necessary to verify the feasibility of the concepts.

Clayton, R. M.↗
NASA NTRS1985

Cost effective launch operations of the SSME

The Space Shuttle Main Engine (SSME) represents the beginning of reusable rocket engine operations in the space transportation system (STS). Steps taken to reduce the overall cost of flight operations of the SSME by improving turnaround operations, extending the life of the engine, and improving the cost effectiveness of overhaul operations at the Canoga Park home plant are described. Ground certification testing to ensure safe launch operations is described, as well as certification extension testing that leads to a service life equivalent to 40 flights. The proven flight record of the SSME, which has demonstrated the utility of the SSME as a key component of America's space transportation system, is discussed.

Klatt, F. P.↗
NASA NTRS1985

SSME failure detection

During ground testing of the Space Shuttle Main Engine (SSME), there have been twenty-six major incidents resulting in substantial hardware damage and loss. Historical characteristics, advances in detection technology, and advances in computing technology led to plans for study of an advanced real time SSME test stand failure detection system which would reduce damage and preserve evidence when a failure with major incident potential occurs. This detection system will speed recognition of dangerous engine operation, and quicken the shutdown decision. The scope of this study, SSME characteristics, SSME test history, the problem definition, and some technical issues will be addressed herein.

Cikanek, H. A., III↗
NASA NTRS1986

Structural tailoring of SSME turbopump blades (SSME/STAEBL)

Computer structural optimization is applied to the design of Space Shuttle main engine turbopump blades. The optimization is implemented by the program SSME/STAEBL. A general description of this program is given. Design optimization studies for typical blade designs are presented.

Rubinstein, R.↗
NASA NTRS1985

Application of intelligent robotic welding systems for fabrication of aerospace hardware

The application of robots to complex on-orbit tasks will require a high degree of adaptability. This paper describes a project which is developing very adaptive robotic systems for welding of the Space Shuttle main engine. A number of the developments which will arise from this program will serve as useful starting points for more advanced systems to be used on-orbit.

Jones, C. S.↗
NASA NTRS1986

Probabilistic structural analysis methods for critical SSME propulsion components

The development of a three-dimensional inelastic analysis methodology for the Space Shuttle main engine (SSME) structural components is described. The methodology is composed of: (1) composite load spectra, (2) probabilistic structural analysis methods, (3) the probabilistic finite element theory, and (4) probabilistic structural analysis. The progress in the development of generic probabilistic models for various individual loads which consist of a steady state load, a periodic load, a random load, and a spike, is discussed. The capabilities of the Numerical Evaluation of Stochastic Structures Under Stress finite element code designed for probabilistic structural analysis of the SSME are examined. Variation principles for formulation probabilistic finite elements and a structural analysis for evaluating the geometric and material properties tolerances on the structural response of turbopump blades are being designed.

Chamis, C. C.↗
NASA NTRS1986

Thermofluid analysis of the SSME preburner using a gas-gas diffusion model for oxygen and hydrogen combustion at supercritical pressures

The paper discusses the thermofluid analysis of the Space Shuttle Main Engine (SSME) fuelside preburner. The governing equations have been solved numerically to predict flow, heat transfer, mixing, and combustion. A two-fluid approach is adopted in which oxygen is regarded as one fluid and hydrogen is regarded as the other fluid. The chemical kinetics is assumed to be very fast so that combustion is primarily controlled by the rate of mixing between oxygen and hydrogen. The preburner pressure is much greater than the critical pressures of oxygen and hydrogen; hence, a gas-gas diffusion model (rather than an evaporation model) has been developed to compute the rate of interphase mixing. Empirical correlations have been incorporated to account for the effect of slip on the interphase exchange. A sensitivity study has been performed with various model parameters. It is observed that the model can predict possibility of incomplete combustion and local regions of high temperatures under steady operating conditions. Some of these anomalies have been observed in actual tests, and the numerical model is useful for understanding possible causes and remedies. At least some measurements are needed for quantitative verification of the model.

Prakash, C.↗
NASA NTRS1986

The evaluation of single crystal superalloys for turbopump blades in the SSME

This paper discusses single-crystal nickel-base superalloys for use in gaseous hydrogen environments, like the Space Shuttle Main Engine (SSME). PWA 1480E was chosen as a candidate alloy based on strength retention in hydrogen environments. Selection of single-crystal-alloy primary and secondary crystallographic axes allows tailoring of the airfoil resonant frequency as a function of orientation. PWA 1480E 111-line primary orientation proved to be the most hydrogen-resistant orientation. By choosing the proper primary and secondary orientation combinations, the fourth excitation mode of the SSME may be avoided.

Bowen, K.↗
NASA NTRS1986

SSME thrust chamber modeling with Navier Stokes equations

The capability of predicting two-dimensional, compressible and reacting flow in the combustion chamber and nozzle of the Space Shuttle Main Engine (SSME) is demonstrated. A nonorthogonal body fitted coordinate system has been used to represent the combustor and nozzle geometry. The Navier-Stokes equations are solved for the entire thrust chamber with the k-epsilon turbulence model accounting for compressibility and large pressure gradients effects. Results of the computational test cases reveal all expected features of the transonic nozzle flows including location of sonic line, internal shock and boundary layer build-up. Calculated performance parameters such as thrust, flow rate, and specific impulse are also in reasonble agreement with available data. The results show promising potential of solving full Navier-Stokes equations with heat transfer and two-phase combustion in truly comprehensive modeling of rocket engines.

Przekwas, A. J.↗
NASA NTRS1986

Space Shuttle filament wound case compressive strength study. I - Testing

Immediately before liftoff, ignition of the Space Shuttle main engines places a significant bending moment on the filament wound cases of the solid rocket booster motors. This results in substantial compressive loading of the aft end of the composite case which, because of attachment requirements, has a complicated design including inserted broadgoods and helical ply dropoffs. To investigate the performance of the filament wound cases during the prelaunch load environment, a comprehensive study was initiated which included both testing and analysis. The results of the test program, which included testing of several full-scale and over three hundred subscale articles, will be described. The test program began with a short development effort to establish appropriate subscale test specimens for determining the material compressive strengths. Once these were established, a more comprehensive test program was initiated to determine the effects on strength of both processing and design changes. Full-scale cases were tested in a simulated prelaunch bending environment in order to validate the analysis predictions. In all tests, special attention was given to observation of the failure sequence which involved a complex process of load transfer from the region of helical ply dropoffs to the broadgood termination region.

Madsen, C. B.↗