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NASA NTRS1986

Transition mixing study

A computer model capable of analyzing the flow field in the transition liner of small gas turbine engines is developed. A FORTRAN code has been assembled from existing codes and physical submodels and used to predict the flow in several test geometries which contain characteristics similar to transition liners, and for which experimental data was available. Comparisons between the predictions and measurements indicate that the code produces qualitative results but that the turbulence models, both K-E and algebraic Reynolds Stress, underestimate the cross-stream diffusion. The code has also been used to perform a numerical experiment to examine the effect of a variety of parameters on the mixing process in transition liners. Comparisons illustrate that geometries with significant curvature show a drift of the jet trajectory toward the convex wall and weaker wake region vortices and decreased penetration for jets located on the convex wall of the liner, when compared to jets located on concave walls. Also shown were the approximate equivalency of angled slots and round holes and a technique by which jet mixing correlations developed for rectangular channels can be used for can geometries.

Reynolds, R.↗

NASA NTRS1998

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (A) Lead handling/exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (B) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (C) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; and (D) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.

Balles, Donald↗

NASA NTRS1999

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (1) Lead handling / exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (2) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (3) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; (4) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.

Balles, Donald↗

NASA NTRS2000

Interfacial Stability of Spherically Converging Plasma Jets for Magnetized Target Fusion

A fusion propulsion scheme has been proposed that makes use of the merging of a spherical distribution of plasma jets to dynamically form a gaseous liner to implode a magnetized target to produce the fusion reaction. In this paper, a study is made of the interfacial stability of the interaction of these jets. Specifically, the Orr-Sommerfeld equation is integrated to obtain the growth rate of a perturbation to the primary flow at the interface between the colliding jets. The results lead to an estimate on the tolerances on the relative flow velocities of the merging plasma jets to form a stable, imploding liner. The results show that the maximum temporal growth rate of the perturbed flow at the jet interface is very small in comparison with the time to full compression of the liner. These data suggest that, as far as the stability of the interface between the merging jets is concerned, the formation of the gaseous liner can withstand velocity variation of the order of 10% between the neighboring jets over the density and temperature ranges investigated.

Thio, Y. C. Francis↗

NASA NTRS2000

Modeling the Compression of Merged Compact Toroids by Multiple Plasma Jets

A fusion propulsion scheme has been proposed that makes use of the merging of a spherical distribution of plasma jets to dynamically form a gaseous liner. The gaseous liner is used to implode a magnetized target to produce the fusion reaction in a standoff manner. In this paper, the merging of the plasma jets to form the gaseous liner is investigated numerically. The Los Alamos SPHINX code, based on the smoothed particle hydrodynamics method is used to model the interaction of the jets. 2-D and 3-D simulations have been performed to study the characteristics of the resulting flow when these jets collide. The results show that the jets merge to form a plasma liner that converge radially which may be used to compress the central plasma to fusion conditions. Details of the computational model and the SPH numerical methods will be presented together with the numerical results.

Thio, Y. C. Francis↗

NASA NTRS2004

Design and Evaluation of Modifications to the NASA Langley Flow Impedance Tube

The need to minimize fan noise radiation from commercial aircraft engine nacelles continues to provide an impetus for developing new acoustic liner concepts. If the full value of such concepts is to be attained, an understanding of grazing flow effects is crucial. Because of this need for improved understanding of grazing flow effects, the NASA Langley Research Center Liner Physics Group has invested a large effort over the past decade into the development of a 2-D finite element method that characterizes wave propagation through a lined duct. The original test section in the Langley Grazing IncidenceTube was used to acquire data needed for implementation of this finite element method. This test section employed a stepper motor-driven axial-traversing bar, embedded in the wall opposite the test liner, to position a flush-mounted microphone at pre-selected locations. Complex acoustic pressure data acquired with this traversing microphone were used to educe the acoustic impedance of test liners using this 2-D finite element method and a local optimization technique. Results acquired in this facility have been extensively reported, and were compared with corresponding results from various U.S. aeroacoustics laboratories in the late 1990 s. Impedance data comparisons acquired from this multi-laboratory study suggested that it would be valuable to incorporate more realistic 3-D aeroacoustic effects into the impedance eduction methodology. This paper provides a description of modifications that have been implemented to facilitate studies of 3-D effects. The two key features of the modified test section are (1) the replacement of the traversing bar and its flush-mounted microphone with an array of 95 fixed-location microphones that are flush-mounted in all four walls of the duct, and (2) the inclusion of a suction device to modify the boundary layer upstream of the lined portion of the duct. The initial results achieved with the modified test section are provided in this report, and a comparison of these results with those achieved using the original test section is used to demonstrate that the data acquisition and analysis with the new test section can be confidently used for impedance eduction.

Jones, Michael G.↗

NASA NTRS2004

New Screening Test Developed for the Blanching Resistance of Copper Alloys

NASA's extensive efforts towards more efficient, safer, and more affordable space transportation include the development of new thrust-cell liner materials with improved capabilities and longer lives. For rocket engines fueled with liquid hydrogen, an important metric of liner performance is resistance to blanching, a phenomenon of localized wastage by cycles of oxidation-reduction due to local imbalance in the oxygen-fuel ratio. The current liner of the Space Shuttle Main Engine combustion chamber, a Cu-3Ag-0.5Zr alloy (NARloy-Z) is degraded in service by blanching. Heretofore, evaluating a liner material for blanching resistance involved elaborate and expensive hot-fire tests performed on rocket test stands. To simplify that evaluation, researchers at the NASA Glenn Research Center developed a screening test that uses simple, in situ oxidation-reduction cycling in a thermogravimetric analyzer (TGA). The principle behind this test is that resistance to oxidation or to the reduction of oxide, or both, implies resistance to blanching. Using this test as a preliminary tool to screen alloys for blanching resistance can improve reliability and save time and money. In this test a small polished coupon is hung in a TGA furnace at the desired (service) temperature. Oxidizing and reducing gases are introduced cyclically, in programmed amounts. Cycle durations are chosen by calibration, such that all copper oxides formed by oxidation are fully reduced in the next reduction interval. The sample weight is continuously acquired by the TGA as usual.

Thomas-Ogbuji, Linus U.↗

NASA NTRS2002

Oxidation Behavior of GRCop-84 Copper Alloy Assessed

NASA's goal of safe, affordable space transportation calls for increased reliability and lifetimes of launch vehicles, and significant reductions of launch costs. The areas targeted for enhanced performance in the next generation of reusable launch vehicles include combustion chambers and nozzle ramps; therefore, the search is on for suitable liner materials for these components. GRCop-84 (Cu-8Cr-4Nb), an advanced copper alloy developed at the NASA Glenn Research Center in conjunction with Case Western Reserve University, is a candidate. The current liner of the Space Shuttle Main Engine is another copper alloy, NARloy-Z (Cu-3Ag-0.1Zr). It provides a benchmark against which to compare the properties of candidate successors. The thermomechanical properties of GRCop-84 have been shown to be superior, and its physical properties comparable, to those of NARloy-Z. However, environmental durability issues control longevity in this application: because copper oxide scales are not highly protective, most copper alloys are quickly consumed in oxygen environments at elevated temperatures. In consequence, NARloy-Z and most other copper alloys are prone to blanching, a degradation process that occurs through cycles of oxidation-reduction as the oxide is repeatedly formed and removed because of microscale fluctuations in the oxygen-hydrogen fuel systems of rocket engines. The Space Shuttle Main Engine lining typically degraded by blanching-induced hot spots that lead to surface roughening, pore formation, and coolant leakage. Therefore, resistance to oxidation and blanching are key requirements for second-generation reusable launch vehicle liners. The rocket engine ambient includes H2 (fuel) and H2O (combustion product) and is, hence, under reduced oxygen partial pressures. Accordingly, our studies were expanded to include oxygen partial pressures as low as 322 parts per million (ppm) at the temperatures likely to be experienced in service. A comparison of 10-hr weight gains of GRCop-84, NARloy-Z, and pure copper in 0.032, 2.2, and 100 percent oxygen from 550 to 750 C is shown. In 2.2 vol% and higher oxygen content, GRCop-84 oxidation was slower than that of NARloy-Z or Cu, but that advantage was lost or diminished in 322-ppm O2. Over longer (50-hr) exposures in 1.0 atm O2, however, the advantage of GRCop-84 increased significantly, its oxidation rate becoming approximately 10 times slower than those of Cu and NARloy-Z from 500 to 700 C. Weight gains were moderate and the kinetics parabolic for all three materials in 2.2 vol% and higher oxygen content; however, in 322-ppm O2, the scales were nonprotective below about 650 C, as reflected in linear kinetics and large weight gains. The superior oxidation resistance of GRCop-84 is likely related to the kinetics of extra oxygen consumption to form the additional oxides of Cr and Nb detected beneath the GRCop-84 oxide layer. While we continue to evaluate the blanching resistance of GRCop-84 in other tests, these oxidation results indicate that GRCop-84 is suitable as a reusable launch vehicle liner, and in applications where it is desired to use a copper alloy but without the risk of oxidative failure. Three bar charts comparing overall specific weight gains by each of the three materials studied. The top chart is for oxidation in 1.0 atm of oxygen, the middle is for 2.2% oxygen (balance argon), and the bottom is for 0.0322% oxygen. GRCop-84 outperforms the other two materials, showing the least weight gain in nearly all cases.

Thomas-Ogbuji, Linus U.↗

NASA NTRS2002

Ceramic Composite Intermediate Temperature Stress-Rupture Properties Improved Significantly

Silicon carbide (SiC) composites are considered to be potential materials for future aircraft engine parts such as combustor liners. It is envisioned that on the hot side (inner surface) of the combustor liner, composites will have to withstand temperatures in excess of 1200 C for thousands of hours in oxidizing environments. This is a severe condition; however, an equally severe, if not more detrimental, condition exists on the cold side (outer surface) of the combustor liner. Here, the temperatures are expected to be on the order of 800 to 1000 C under high tensile stress because of thermal gradients and attachment of the combustor liner to the engine frame (the hot side will be under compressive stress, a less severe stress-state for ceramics). Since these composites are not oxides, they oxidize. The worst form of oxidation for strength reduction occurs at these intermediate temperatures, where the boron nitride (BN) interphase oxidizes first, which causes the formation of a glass layer that strongly bonds the fibers to the matrix. When the fibers strongly bond to the matrix or to one another, the composite loses toughness and strength and becomes brittle. To increase the intermediate temperature stress-rupture properties, researchers must modify the BN interphase. With the support of the Ultra-Efficient Engine Technology (UEET) Program, significant improvements were made as state-of-the-art SiC/SiC composites were developed during the Enabling Propulsion Materials (EPM) program. Three approaches were found to improve the intermediate-temperature stress-rupture properties: fiber-spreading, high-temperature silicon- (Si) doped boron nitride (BN), and outside-debonding BN.

Morscher, Gregory N.↗

NASA NTRS2003

NiAl Coatings Investigated for Use in Reusable Launch Vehicles

As part of its major investment in the area of advanced space transportation, NASA is developing new technologies for use in the second- and third-generation designs of reusable launch vehicles. Among the prototype rocket engines being considered for these launch vehicles are those designed to use liquid hydrogen as the fuel and liquid oxygen as the oxidizer. Advanced copper alloys, such as copper-chromium-niobium (Cu-8(at.%)Cr- 4(at.%)Nb, also referred to as GRCop-84), which was invented at the NASA Glenn Research Center, are being considered for use as liner materials in the combustion chambers and nozzle ramps of these engines. However, previous experience has shown that, in rocket engines using liquid hydrogen and liquid oxygen, copper alloys are subject to a process called blanching, where the material undergoes environmental attack under the action of the combustion gases. In addition, the copper alloy liners undergo thermomechanical fatigue, which often results in an initially square cooling channel deforming into a dog-house shape. Clearly, there is an urgent need to develop new coatings to protect copper liners from environmental attack inside rocket chambers and to lower the temperature of the liners to reduce the probability of deformation and failure by thermomechanical fatigue.

Raj, Sai V.↗

NASA NTRS2005

VPS Process for Copper Components in Thrust Chamber Assemblies

For several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc., (PPI) to fabricate thrust chamber liners with GRCop-84. Using the vacuum plasma spray (VPS) process, chamber liners of a variety of shapes and sizes have been created. Each has been formed as a functional gradient material (FGM) that creates a unique protective layer of NiCrAlY on the GRCop-84 liner s hot wall surface. Hot-fire testing was successfully conducted on a subscale unit to demonstrate the liner's durability and performance. Similar VPS technology has also been applied to create functional gradient coatings (FGC) on copper injector faceplates. Protective layers of NiCrAlY and zirconia were applied to both coaxial and impinging faceplate designs. Hot-fire testing is planned for these coated injectors in April 2005. The resulting material systems for both copper alloy components allows them to operate at higher temperatures with improved durability and operating margins.

Elam, Sandra↗

NASA NTRS1994

Waste gas storage

Method for storing a waste gas mixture comprised of nitrogen, oxygen, carbon dioxide, and inert gases, the gas mixture containing corrosive contaminants including inorganic acids and bases and organic solvents, and derived from space station operations. The gas mixture is stored under pressure in a vessel formed of a filament wound composite overwrap on a metal liner, the metal liner being pre-stressed in compression by the overwrap, thereby avoiding any tensile stress in the liner, and preventing stress corrosion cracking of the liner during gas mixture storage.

Vickers, Brian D.↗

NASA NTRS2009

A Computational and Experimental Study of Resonators in Three Dimensions

In a previous work by the present authors, a computational and experimental investigation of the acoustic properties of two-dimensional slit resonators was carried out. The present paper reports the results of a study extending the previous work to three dimensions. This investigation has two basic objectives. The first is to validate the computed results from direct numerical simulations of the flow and acoustic fields of slit resonators in three dimensions by comparing with experimental measurements in a normal incidence impedance tube. The second objective is to study the flow physics of resonant liners responsible for sound wave dissipation. Extensive comparisons are provided between computed and measured acoustic liner properties with both discrete frequency and broadband sound sources. Good agreements are found over a wide range of frequencies and sound pressure levels. Direct numerical simulation confirms the previous finding in two dimensions that vortex shedding is the dominant dissipation mechanism at high sound pressure intensity. However, it is observed that the behavior of the shed vortices in three dimensions is quite different from those of two dimensions. In three dimensions, the shed vortices tend to evolve into ring (circular in plan form) vortices, even though the slit resonator opening from which the vortices are shed has an aspect ratio of 2.5. Under the excitation of discrete frequency sound, the shed vortices align themselves into two regularly spaced vortex trains moving away from the resonator opening in opposite directions. This is different from the chaotic shedding of vortices found in two-dimensional simulations. The effect of slit aspect ratio at a fixed porosity is briefly studied. For the range of liners considered in this investigation, it is found that the absorption coefficient of a liner increases when the open area of the single slit is subdivided into multiple, smaller slits.

Tam, C. K. W.↗

NASA NTRS2009

Assessment of Soft Vane and Metal Foam Engine Noise Reduction Concepts

Two innovative fan-noise reduction concepts developed by NASA are presented - soft vanes and over-the-rotor metal foam liners. Design methodologies are described for each concept. Soft vanes are outlet guide vanes with internal, resonant chambers that communicate with the exterior aeroacoustic environment via a porous surface. They provide acoustic absorption via viscous losses generated by interaction of unsteady flows with the internal solid structure. Over-the-rotor metal foam liners installed at or near the fan rotor axial plane provide rotor noise absorption. Both concepts also provide pressure-release surfaces that potentially inhibit noise generation. Several configurations for both concepts are evaluated with a normal incidence tube, and the results are used to guide designs for implementation in two NASA fan rigs. For soft vanes, approximately 1 to 2 dB of broadband inlet and aft-radiated fan noise reduction is achieved. For over-the-rotor metal foam liners, up to 3 dB of fan noise reduction is measured in the low-speed fan rig, but minimal reduction is measured in the high-speed fan rig. These metal foam liner results are compared with a static engine test, in which inlet sound power level reductions up to 5 dB were measured. Brief plans for further development are also provided.

Jones, Michael G.↗

NASA NTRS2011

Composite Overwrapped Pressure Vessels, A Primer

Due to the extensive amount of detailed information that has been published on composite overwrapped pressure vessels (COPVs), this document has been written to serve as a primer for those who desire an elementary knowledge of COPVs and the factors affecting composite safety. In this application, the word "composite" simply refers to a matrix of continuous fibers contained within a resin and wrapped over a pressure barrier to form a vessel for gas or liquid containment. COPVs are currently used at NASA to contain high pressure fluids in propulsion, science experiments, and life support applications. They have a significant weight advantage over all metal vessels but require unique design, manufacturing, and test requirements. COPVs also involve a much more complex mechanical understanding due to the interplay between the composite overwrap and the inner liner. A metallic liner is typically used in a COPV as a fluid permeation barrier. The liner design concepts and requirements have been borrowed from all-metal vessels. However, application of metallic vessel design standards to a very thin liner is not straightforward. Different failure modes exist for COPVs than for all-metal vessels, and understanding of these failure modes is at a much more rudimentary level than for metal vessels.

McLaughlan, Pat B.↗

NASA NTRS2012

Evaluation of Wall Boundary Conditions for Impedance Eduction Using a Dual-Source Method

The accuracy of the Ingard-Myers boundary condition and a recently proposed modified Ingard-Myers boundary condition is evaluated for use in impedance eduction under the assumption of uniform mean flow. The evaluation is performed at three centerline Mach numbers, using data acquired in a grazing flow impedance tube, using both upstream and downstream propagating sound sources, and on a database of test liners for which the expected behavior of the impedance spectra is known. The test liners are a hard-wall insert consisting of 12.6 mm thick aluminum, a linear liner without a facesheet consisting of a number of small diameter but long cylindrical channels embedded in a ceramic material, and two conventional nonlinear liners consisting of a perforated facesheet bonded to a honeycomb core. The study is restricted to a frequency range for which only plane waves are cut on in the hard-wall sections of the flow impedance tube. The metrics used to evaluate each boundary condition are 1) how well it educes the same impedance for upstream and downstream propagating sources, and 2) how well it predicts the expected behavior of the impedance spectra over the Mach number range. The primary conclusions of the study are that the same impedance is educed for upstream and downstream propagating sources except at the highest Mach number, that an effective impedance based on both the upstream and downstream measurements is more accurate than an impedance based on the upstream or downstream data alone, and that the Ingard-Myers boundary condition with an effective impedance produces results similar to that achieved with the modified Ingard-Myers boundary condition.

Watson, W. R.↗

NASA NTRS2012

Reliability of COPVs Accounting for Margin of Safety on Design Burst

In this paper, the stress rupture reliability of Carbon/Epoxy Composite Overwrapped Pressure Vessels (COPVs) is examined utilizing the classic Phoenix model and accounting for the differences between the design and the actual burst pressure, and the liner contribution effects. Stress rupture life primarily depends upon the fiber stress ratio which is defined as the ratio of stress in fibers at the maximum expected operating pressure to actual delivered fiber strength. The actual delivered fiber strength is calculated using the actual burst pressures of vessels established through burst tests. However, during the design phase the actual burst pressure is generally not known and to estimate the reliability of the vessels calculations are usually performed based upon the design burst pressure only. Since the design burst is lower than the actual burst, this process yields a much higher value for the stress ratio and consequently a conservative estimate for the reliability. Other complications arise due to the fact that the actual burst pressure and the liner contributions have inherent variability and therefore must be treated as random variables in order to compute the stress rupture reliability. Furthermore, the model parameters, which have to be established based on stress rupture tests of subscale vessels or coupons, have significant variability as well due to limited available data and hence must be properly accounted for. In this work an assessment of reliability of COPVs including both parameter uncertainties and physical variability inherent in liner and overwrap material behavior is made and estimates are provided in terms of degree of uncertainty in the actual burst pressure and the liner load sharing.

Murthy, Pappu L.N.↗

NASA NTRS2017

Impedance Eduction in Large Ducts Containing Higher-Order Modes and Grazing Flow

Impedance eduction test data are acquired in ducts with small and large cross-sectional areas at the NASA Langley Research Center. An improved data acquisition system in the large duct has resulted in increased control of the acoustic energy in source modes and more accurate resolution of higher-order duct modes compared to previous tests. Two impedance eduction methods that take advantage of the improved data acquisition to educe the liner impedance in grazing flow are presented. One method measures the axial propagation constant of a dominant mode in the liner test section (by implementing the Kumarsean and Tufts algorithm) and educes the impedance from an exact analytical expression. The second method solves numerically the convected Helmholtz equation and minimizes an objective function to obtain the liner impedance. The two methods are tested first on data synthesized from an exact mode solution and then on measured data. Results show that when the methods are applied to data acquired in the larger duct with a dominant higher-order mode, the same impedance spectra are educed as that obtained in the small duct where only the plane wave mode propagates. This result holds for each higher-order mode in the large duct provided that the higher-order mode is sufficiently attenuated by the liner.

Watson, Willie R.↗