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Transient heat transfer and thermodynamic behavior analysis for Apollo service module propulsion system - fuel cell effect on overheating
Current problems involving the structural integrity of propulsion systems, and proposed approaches to solving them, are reviewed. Areas investigated include the stall hammershock at the engine inlet, distortion-induced vibration in fan and compressor blading, modeling engine static structures with conical-shell finite elements, design and development of low-cost, self-contained bearing lubrication systems for turbine engines, and roller bearing slip and skidding damage. Individual items are announced in this issue.
The design and testing of the over the wing engine, a high bypass, geared turbofan engine, are discussed. The propulsion system performance is examined for uninstalled performance and installed performance. The fan aerodynamic performance and the D nozzle and reverser thrust performance are evaluated.
Standard leak detection methods at ambient temperature have been developed in order to prevent excessive leakage from the Space Shuttle liquid oxygen and liquid hydrogen Main Propulsion System. Unacceptable hydrogen leakage was encountered on the Columbia and Atlantis flight vehicles in the summer of 1990 after the standard leak check requirements had been satisfied. The leakage was only detectable when the fuel system was exposed to subcooled liquid hydrogen during External Tank loading operations. Special instrumentation and analytical tools were utilized during a series of propellant tanking tests in order to identify the sources of the hydrogen leakage. After the leaks were located and corrected, the physical characteristics of the leak sources were analyzed in an effort to understand how the discrepancies were introduced and why the leakage had evaded the standard leak detection methods. As a result of the post-leak analysis, corrective actions and leak detection improvements have been implemented in order to preclude a similar incident.
The National Aeronautics and Space Administration conducted a full scale ice crystal icing turbofan engine test in the NASA Glenn Research Centers Propulsion Systems Laboratory (PSL) Facility in February 2013. Honeywell Engines supplied the test article, an obsolete, unmodified Lycoming ALF502-R5 turbofan engine serial number LF01 that experienced an un-commanded loss of thrust event while operating at certain high altitude ice crystal icing conditions. These known conditions were duplicated in the PSL for this testing.
This paper describes a gas turbine simulation system which utilizes the newly developed Java language environment software system. The system provides an interactive graphical environment which allows the quick and efficient construction and analysis of arbitrary gas turbine propulsion systems. The simulation system couples a graphical user interface, developed using the Java Abstract Window Toolkit, and a transient, space- averaged, aero-thermodynamic gas turbine analysis method, both entirely coded in the Java language. The combined package provides analytical, graphical and data management tools which allow the user to construct and control engine simulations by manipulating graphical objects on the computer display screen. Distributed simulations, including parallel processing and distributed database access across the Internet and World-Wide Web (WWW), are made possible through services provided by the Java environment.
This technical publication describes the methodology, model, software tool, input data, and analysis result that support aerospace design reliability studies. The focus of these activities is on propulsion systems mechanical design reliability. The goal of these activities is to support design from a reliability perspective. Paralleling performance analyses in schedule and method, this requires the proper use of metrics in a validated reliability model useful for design, sensitivity, and trade studies. Design reliability analysis in this view is one of several critical design functions. A design reliability method is detailed and two example analyses are provided-one qualitative and the other quantitative. The use of aerospace and commercial data sources for quantification is discussed and sources listed. A tool that was developed to support both types of analyses is presented. Finally, special topics discussed include the development of design criteria, issues of reliability quantification, quality control, and reliability verification.
NASA Glenn Research Center is performing activities to support the unique needs of hollow cathode development and testing for the Advanced Electric Propulsion System (AEPS). Three existing vacuum facilities have been outfitted as cathode test facilities, and each will serve a different role in upcoming testing. Vacuum Facility 67 is being developed to serve as a long-duration test facility for the Engineering Development Unit cathode, which is to be delivered by the AEPS contractor. It will feature a thruster-like magnetic field simulator and cold-cycle capability via a liquid nitrogen-cooled cold plate. Vacuum Facility 17 is being developed as a test facility for short- to medium-duration experiments in order to provide auxiliary support for the long-duration testing. It will feature a magnetic field simulator but not cold-cycling. Finally, Vacuum Facility 1 will be a high-pumping speed cathode development environment, and will feature an array of plasma and temperature diagnostics. In addition to the facility preparation work, a new cathode, referred to as the Mark II, has been designed. The Mark II is an evolution of the Technology Demonstration Unit cathodes that better evokes the geometry, fabrication, and construction of the forthcoming Engineering Development Unit. This cathode serves as a transition between the Technology Demonstration Unit cathodes used during early thruster development and the forthcoming Engineering Development Unit cathodes. It will be used as a means of verifying the new test facilities prior to arrival of Engineering Development Unit hardware. Details of the Mark II design and key features are presented, as well as details of future work to be performed.
NASA Glenn Research Center is performing activities to support the unique needs of hollow cathode development and testing for the Advanced Electric Propulsion System (AEPS). Three existing vacuum facilities have been outfitted as cathode test facilities, and each will serve a different role in upcoming testing. Vacuum Facility 67 is being developed to serve as a long-duration test facility for the Engineering Development Unit cathode, which is to be delivered by the AEPS contractor. It will feature a thruster-like magnetic field simulator and cold-cycle capability via a liquid nitrogen-cooled cold plate. Vacuum Facility 17 is being developed as a test facility for short- to medium-duration experiments in order to provide auxiliary support for the long-duration testing. It will feature a magnetic field simulator but not cold-cycling. Finally, Vacuum Facility 1 will be a high-pumping speed cathode development environment, and will feature an array of plasma and temperature diagnostics. In addition to the facility preparation work, a new cathode, referred to as the Mark II, has been designed. The Mark II is an evolution of the Technology Demonstration Unit cathodes that better evokes the geometry, fabrication, and construction of the forthcoming Engineering Development Unit. This cathode serves as a transition between the Technology Demonstration Unit cathodes used during early thruster development and the forthcoming Engineering Development Unit cathodes. It will be used as a means of verifying the new test facilities prior to arrival of Engineering Development Unit hardware. Details of the Mark II design and key features are presented, as well as details of future work to be performed.
This paper evaluates simulation predictions against experimental test data of icing clouds that were produced during 2018 ice crystal icing physics tests conducted at the NASA Propulsion Systems Laboratory icing wind tunnel. Aero-thermal and cloud parameters are set and known upstream at the tunnel inlet and spray system, but change as the cloud and air thermodynamically interact as the flowing masses reach the tunnel test section. Utilizing the ANSYS Fluent Discrete Phase Model function, 3D computational fluid dynamics (CFD) simulations were performed, capturing the thermodynamic interactions between the test parameters, and providing predictions of the aero thermal and cloud conditions at the tunnel test section. Simulation predictions were compared with test data that were measured at the tunnel exit plane. Evaluations focused on the cloud concentration (total water content), humidity content, and air temperature. CFD simulation predictions showed areas of agreement and disagreement. Simulations showed that cloud concentration profiles at the test section are strongly related to the initial spray nozzle pattern used at the tunnel inlet. Experimental data suggest that greater dispersion of the cloud occurred as the simulated cloud predicted areas of high and low cloud concentration compared to test data profiles. Simulations, however, captured the magnitude and location of the change in humidity content and the change in air temperature due to the presence of the cloud reasonably well, when compared to test data. This result would suggest that while the ANSYS simulation did not fully predict the spreading of the cloud as measured during experiment, it did capture evaporation and the molecular movements of air and vapor relatively well.
This paper evaluates simulation predictions against experimental test data of icing clouds that were produced during 2018 ice crystal icing physics tests conducted at the NASA Propulsion Systems Laboratory icing wind tunnel. Aero-thermal and cloud parameters are set and known upstream at the tunnel inlet and spray system, but change as the cloud and air thermodynamically interact as the flowing masses reach the tunnel test section. Utilizing the ANSYS Fluent Discrete Phase Model function, 3D computational fluid dynamics (CFD) simulations were performed, capturing the thermodynamic interactions between the test parameters, and providing predictions of the aero thermal and cloud conditions at the tunnel test section. Simulation predictions were compared with test data that were measured at the tunnel exit plane. Evaluations focused on the cloud concentration (total water content), humidity content, and air temperature. CFD simulation predictions showed areas of agreement and disagreement. Simulations showed that cloud concentration profiles at the test section are strongly related to the initial spray nozzle pattern used at the tunnel inlet. Experimental data suggest that greater dispersion of the cloud occurred as the simulated cloud predicted areas of high and low cloud concentration compared to test data profiles. Simulations, however, captured the magnitude and location of the change in humidity content and the change in air temperature due to the presence of the cloud reasonably well, when compared to test data. This result would suggest that while the ANSYS simulation did not fully predict the spreading of the cloud as measured during experiment, it did capture evaporation and the molecular movements of air and vapor relatively well.
The first 80 days after launch of the Dawn mission were dedicated to the checkout of the spacecraft with a major emphasis on the ion propulsion system. All three ion thrusters, all three thruster-gimbal assemblies, both power processor units, both digital interface and control units, and the entire xenon feed system were completely checked out and every component was found to be in good health. Direct thrust measurements agreed well with preflight expected values for all three thrusters over the entire throttle range. Thruster electrical operating parameters and power processor units efficiencies also agreed well with preflight expected values based on acceptance test data. Two of the three ion thrusters were fully checked out within 30 days after launch. Checkout of all three thrusters was completed 64 days after launch. Deterministic thrusting with the IPS began on December 17, 2007.
Exhaust nozzle noise suppression program for supersonic transport propulsion systems
There is a growing interest in the use of fuel cells as a power source for all-electric aircraft propulsion as a means to substantially reduce or eliminate environmentally harmful emissions. Among the technologies under consideration for these concepts are advanced proton exchange membrane and solid oxide fuel cells, alternative fuels and fuel processing, and fuel storage. This paper summarizes the results of a first-order feasibility study for an all-electric personal air vehicle utilizing a fuel cell-powered propulsion system. A representative aircraft with an internal combustion engine was chosen as a baseline to provide key parameters to the study, including engine power and subsystem mass, fuel storage volume and mass, and aircraft range. The engine, fuel tank, and associated ancillaries were then replaced with a fuel cell subsystem. Various configurations were considered including: a proton exchange membrane (PEM) fuel cell with liquid hydrogen storage; a direct methanol PEM fuel cell; and a direct internal reforming solid oxide fuel cell (SOFC)/turbine hybrid system using liquid methane fuel. Each configuration was compared to the baseline case on a mass and range basis.
There is a growing interest in the use of fuel cells as a power source for all-electric aircraft propulsion as a means to substantially reduce or eliminate environmentally harmful emissions. Among the technologies under consideration for these concepts are advanced proton exchange membrane and solid oxide fuel cells, alternative fuels and fuel processing, and fuel storage. This paper summarizes the results of a first-order feasibility study for an all-electric personal air vehicle utilizing a fuel cell-powered propulsion system. A representative aircraft with an internal combustion engine was chosen as a baseline to provide key parameters to the study, including engine power and subsystem mass, fuel storage volume and mass, and aircraft range. The engine, fuel tank, and associated ancillaries were then replaced with a fuel cell subsystem. Various configurations were considered including: a proton exchange membrane (PEM) fuel cell with liquid hydrogen storage; a direct methanol PEM fuel cell; and a direct internal reforming solid oxide fuel cell (SOFC)/turbine hybrid system using liquid methane fuel. Each configuration was compared to the baseline case on a mass and range basis.
The impact of the performance and density of on-board propellants on science payload mass of Discovery Program class missions is evaluated. A propulsion system dry mass model, anchored on flight-weight system data from the Near Earth Asteroid Rendezvous mission is used. This model is used to evaluate the performance of liquid oxygen, hydrogen peroxide, hydroxylammonium nitrate, and oxygen difluoride oxidizers with hydrocarbon and metal hydride fuels. Results for the propellants evaluated indicate that the state-of-art, Earth Storable propellants with high performance rhenium engine technology in both the axial and attitude control systems has performance capabilities that can only be exceeded by liquid oxygen/hydrazine, liquid oxygen/diborane and oxygen difluoride/diborane propellant combinations. Potentially lower ground operations costs is the incentive for working with nontoxic propellant combinations.
A method and system are provided for propelling an aerodynamic vehicle into space. The aerodynamic vehicle uses a nuclear-based thermal rocket (NTR) propulsion system capable of producing a hydrogen exhaust. A flow of air is introduced into the hydrogen exhaust to augment the thrust force at speeds of the vehicle up to approximately Mach 6. When the speed of the vehicle is approximately Mach 6 and the altitude of the vehicle is approximately 40 kilometers, the flow of air is stopped and the vehicle is propelled into space using only the NTR.
This document is a guide to New Frontiers mission proposal teams. The document describes the development and status of the NASA's Evolutionary Xenon Thruster (NEXT) ion propulsion system (IPS) technology, its application to planetary missions, and the process anticipated to transition NEXT to the first flight mission.