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NASA NTRS2011

Using Innovative Technologies for Manufacturing Rocket Engine Hardware

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As the United States enters into the next space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, rapid manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on NASA s Space Launch System (SLS) upper stage engine, J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator (GG) discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using a workhorse gas generator (WHGG) test fixture at MSFC's East Test Area, the duct was subjected to extreme J-2X hot gas environments during 7 tests for a total of 537 seconds of hot-fire time. The duct underwent extensive post-test evaluation and showed no signs of degradation. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Betts, E. M.↗

NASA NTRS2006

Ares 1 First Stage Design, Development, Test, and Evaluation

The Ares I Crew Launch Vehicle (CLV) is an integral part of NASA s exploration architecture that will provide crew and cargo access to the International Space Station as well as low earth orbit support for lunar missions. Currently in the system definition phase, the CLV is planned to replace the Space Shuttle for crew transport in the post 2010 time frame. It is comprised of a solid rocket booster (SRB) first stage derived from the current Space Shuttle SRB, a liquid oxygen/hydrogen fueled second stage utilizing a derivative of the Apollo upper stage engine for propulsion, and a Crew Exploration Vehicle (CEV) composed of command and service modules. This paper deals with current design, development, test, and evaluation planning for the CLV first stage SRB. Described are the current overall point-of-departure design and booster subsystems, systems engineering approach, and milestone schedule requirements.

Williams, Tom↗

NASA NTRS2015

Use of Generalized Fluid System Simulation Program (GFSSP) for Teaching and Performing Senior Design Projects at the Educational Institutions

This paper describes the experience of the authors in using the Generalized Fluid System Simulation Program (GFSSP) in teaching Design of Thermal Systems class at University of Alabama in Huntsville. GFSSP is a finite volume based thermo-fluid system network analysis code, developed at NASA/Marshall Space Flight Center, and is extensively used in NASA, Department of Defense, and aerospace industries for propulsion system design, analysis, and performance evaluation. The educational version of GFSSP is freely available to all US higher education institutions. The main purpose of the paper is to illustrate the utilization of this user-friendly code for the thermal systems design and fluid engineering courses and to encourage the instructors to utilize the code for the class assignments as well as senior design projects. The need for a generalized computer program for thermofluid analysis in a flow network has been felt for a long time in aerospace industries. Designers of thermofluid systems often need to know pressures, temperatures, flow rates, concentrations, and heat transfer rates at different parts of a flow circuit for steady state or transient conditions. Such applications occur in propulsion systems for tank pressurization, internal flow analysis of rocket engine turbopumps, chilldown of cryogenic tanks and transfer lines, and many other applications of gas-liquid systems involving fluid transients and conjugate heat and mass transfer. Computer resource requirements to perform time-dependent, three-dimensional Navier-Stokes computational fluid dynamic (CFD) analysis of such systems are prohibitive and therefore are not practical. Available commercial codes are generally suitable for steady state, single-phase incompressible flow. Because of the proprietary nature of such codes, it is not possible to extend their capability to satisfy the above-mentioned needs. Therefore, the Generalized Fluid System Simulation Program (GFSSP1) has been developed at NASA Marshall Space Flight Center (MSFC) as a general fluid flow system solver capable of handling phase changes, compressibility, mixture thermodynamics and transient operations. It also includes the capability to model external body forces such as gravity and centrifugal effects in a complex flow network. The objectives of GFSSP development are: a) to develop a robust and efficient numerical algorithm to solve a system of equations describing a flow network containing phase changes, mixing, and rotation; and b) to implement the algorithm in a structured, easy-to-use computer program. The analysis of thermofluid dynamics in a complex network requires resolution of the system into fluid nodes and branches, and solid nodes and conductors as shown in Figure 1. Figure 1 shows a schematic and GFSSP flow circuit of a counter-flow heat exchanger. Hot nitrogen gas is flowing through a pipe, colder nitrogen is flowing counter to the hot stream in the annulus pipe and heat transfer occurs through metal tubes. The problem considered is to calculate flowrates and temperature distributions in both streams. GFSSP has a unique data structure, as shown in Figure 2, that allows constructing all possible arrangements of a flow network with no limit on the number of elements. The elements of a flow network are boundary nodes where pressure and temperature are specified, internal nodes where pressure and temperature are calculated, and branches where flowrates are calculated. For conjugate heat transfer problems, there are three additional elements: solid node, ambient node, and conductor. The solid and fluid nodes are connected with solid-fluid conductors. GFSSP solves the conservation equations of mass and energy, and equation of state in internal nodes to calculate pressure, temperature and resident mass. The momentum conservation equation is solved in branches to calculate flowrate. It also solves for energy conservation equations to calculate temperatures of solid nodes. The equations are coupled and nonlinear; therefore, they are solved by an iterative numerical scheme. GFSSP employs a unique numerical scheme known as simultaneous adjustment with successive substitution (SASS), which is a combination of Newton-Raphson and successive substitution methods. The mass and momentum conservation equations and the equation of state are solved by the Newton-Raphson method while the conservation of energy and species are solved by the successive substitution method. GFSSP is linked with two thermodynamic property programs, GASP2 and WASP3 and GASPAK4, that provide thermodynamic and thermophysical properties of selected fluids. Both programs cover a range of pressure and temperature that allows fluid properties to be evaluated for liquid, liquid-vapor (saturation), and vapor region. GASP and WASP provide properties of 12 fluids. GASPAK includes a library of 36 fluids. GFSSP has three major parts. The first part is the graphical user interface (GUI), visual thermofluid analyzer of systems and components (VTASC). VTASC allows users to create a flow circuit by a 'point and click' paradigm. It creates the GFSSP input file after the completion of the model building process. GFSSP's GUI provides the users a platform to build and run their models. It also allows post-processing of results. The network flow circuit is first built using three basic elements: boundary node, internal node, and branch.

Majumdar, A. K.↗

NASA NTRS2005

Using CFD as a Rocket Injector Design Tool: Recent Progress at Marshall Space Flight Center

New programs are forcing American propulsion system designers into unfamiliar territory. For instance, industry s answer to the cost and reliability goals set out by the Next Generation Launch Technology Program are engine concepts based on the Oxygen- Rich Staged Combustion Cycle. Historical injector design tools are not well suited for this new task. The empirical correlations do not apply directly to the injector concepts associated with the ORSC cycle. These legacy tools focus primarily on performance with environment evaluation a secondary objective. Additionally, the environmental capability of these tools is usually one-dimensional while the actual environments are at least two- and often three-dimensional. CFD has the potential to calculate performance and multi-dimensional environments but its use in the injector design process has been retarded by long solution turnaround times and insufficient demonstrated accuracy. This paper has documented the parallel paths of program support and technology development currently employed at Marshall Space Flight Center in an effort to move CFD to the forefront of injector design. MSFC has established a long-term goal for use of CFD for combustion devices design. The work on injector design is the heart of that vision and the Combustion Devices CFD Simulation Capability Roadmap that focuses the vision. The SRL concept, combining solution fidelity, robustness and accuracy, has been established as a quantitative gauge of current and desired capability. Three examples of current injector analysis for program support have been presented and discussed. These examples are used to establish the current capability at MSFC for these problems. Shortcomings identified from this experience are being used as inputs to the Roadmap process. The SRL evaluation identified lack of demonstrated solution accuracy as a major issue. Accordingly, the MSFC view of code validation and current MSFC-funded validation efforts were discussed in some detail. The objectives of each effort were noted. Issues relative to code validation for injector design were discussed in some detail. The requirement for CFD support during the design of the experiment was noted and discussed in terms of instrumentation placement and experimental rig uncertainty. In conclusion, MSFC has made significant progress in the last two years in advancing CFD toward the goal of application to injector design. A parallel effort focused on program support and technology development via the SCIT Task have enabled the progress.

Tucker, Kevin↗

NASA NTRS2007

Scaling of Performance in Liquid Propellant Rocket Engine Combustors

This paper discusses scaling of combustion and combustion performance in liquid propellant rocket engine combustion devices. In development of new combustors, comparisons are often made between predicted performance in a new combustor and measured performance in another combustor with different geometric and thermodynamic characteristics. Without careful interpretation of some key features, the comparison can be misinterpreted and erroneous information used in the design of the new device. This paper provides a review of this performance comparison, including a brief review of the initial liquid rocket scaling research conducted during the 1950s and 1960s, a review of the typical performance losses encountered and how they scale, a description of the typical scaling procedures used in development programs today, and finally a review of several historical development programs to see what insight they can bring to the questions at hand.

Hulka, James R.↗

NASA NTRS2008

Scaling of Performance in Liquid Propellant Rocket Engine Combustion Devices

Hulka, James R.↗

NASA NTRS1976

Space Shuttle Main Propulsion System

The Space Shuttle Main Propulsion System provides the impulse to transfer the reusable Orbiter of the Space Shuttle Transportation system and its payload from earth to earth orbit. Both cryogenic and solid rocket propulsion systems are utilized. The selected systems are characterized by (1) reusability wherever possible to reduce program cost, (2) design pressures, and other important design parameters, for the liquid propellant engine significantly higher than past programs for increased performance, and (3) advanced materials and manufacturing processes to withstand the extreme environments. The approaches for solution of these varied problems are emphasized.

Wood, C. C.↗

NASA NTRS1979

Bistable (latching) solenoid actuated propellant isolation valve

The design, fabrication, assembly and test of a development configuration bistable (latching) solenoid actuated propellant isolation valve suitable for the control hydrazine and liquid fluorine to an 800 pound thrust rocket engine is described. The valve features a balanced poppet, utilizing metal bellows, a hard poppet/seat interface and a flexure support system for the internal moving components. This support system eliminates sliding surfaces, thereby rendering the valve free of self generated particles.

Wichmann, H.↗

NASA NTRS1984

Supersonic-Nozzle Shock-Wave Analysis

Analytical procedure used to modify design of high-pressure-ratio nozzles to reduce vibration during start-up and shutdown. Nozzles used in jet engines, laser nozzles and diffusers, wind tunnels, gas turbines and rocket engines.

Wagner, W. R.↗

NASA NTRS1999

Probabilistic Structural Analysis of the SRB Aft Skirt External Fitting Modification

NASA has funded several major programs (the PSAM Project is an example) to develop Probabilistic Structural Analysis Methods and tools for engineers to apply in the design and assessment of aerospace hardware. A probabilistic finite element design tool, known as NESSUS, is used to determine the reliability of the Space Shuttle Solid Rocket Booster (SRB) aft skirt critical weld. An external bracket modification to the aft skirt provides a comparison basis for examining the details of the probabilistic analysis and its contributions to the design process.

Townsend, John S.↗

NASA NTRS2011

Measuring Fluctuating Pressure Levels and Vibration Response in a Jet Plume

The characterization of loads due to solid rocket motor plume impingement allows for moreaccurate analyses of components subjected to such an environment. Typically, test verification of predicted loads due to these conditions is widely overlooked or unsuccessful. ATA Engineering, Inc., performed testing during a solid rocket motor firing to obtain acceleration and pressure responses in the hydrodynamic field surrounding the jet plume. The test environment necessitated a robust design to facilitate measurements being made in close proximity to the jet plume. This paper presents the process of designing a test fixture and an instrumentation package that could withstand the solid rocket plume environment and protect the required instrumentation.

Osterholt, Douglas J.↗

NASA NTRS1999

Rocket-Based Combined-Cycle Propulsion Technology for Access-to-Space Applications

NASA's Office of Aero-Space Technology (OAST) established three major goals, referred to as, "The Three Pillars for Success". The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center (MSFC) in Huntsville, Ala. focuses on future space transportation technologies under the "Access to Space" pillar. One of the main activities over the past three years has been on advancing the hydrogen fueled rocket-based combined cycle (RBCC) technologies. The RBCC effort that was completed early this year was the initial step leading to flight demonstrations of the technology for space launch vehicle propulsion. Aerojet and Boeing-Rocketdyne designed, built and ground tested their RBCC engine concepts. In addition, ASTROX, Georgia Institute of Technology, McKinney Associates, Pennsylvania State University (PSU), and University of Alabama in Huntsville conducted supporting activities. The RBCC activity included ground testing of components (e.g., injectors, thrusters, ejectors and inlets) and integrated flowpaths. Inlet testing was performed at the Lewis Research Center's 1 x 1 wind tunnel. All direct connect and free-jet engine testing were conducted at the GASL facilities on Long Island, New York. Testing spanned the Mach range from sea level static to Mach 8. Testing of the rocket-only mode, simulating the final phase of the ascent mission profile, was also performed. The originally planned work on these contracts was completed in 1999. Follow-on activities have been initiated for both hydrogen and hydrocarbon fueled RBCC concepts. Studies to better understand system level issues with the integration of RBCC propulsion with earth-to-orbit vehicles have also been conducted. This paper describes the status, progress and future plans of the RBCC activities funded by NASA/MSFC with a major focus on the benefits of utilizing air-breathing combined-cycle propulsion in access-to-space applications.

Hueter, Uwe↗

NASA NTRS2010

Rocket + Science = Dialogue

It's a cliche that rocket engineers and space scientists don t see eye-to-eye. That goes double for rocket engineers working on human spaceflight and scientists working on space telescopes and planetary probes. They work fundamentally different problems but often feel that they are competing for the same pot of money. Put the two groups together for a weekend, and the results could be unscientific or perhaps combustible. Fortunately, that wasn't the case when NASA put heavy lift launch vehicle designers together with astronomers and planetary scientists for two weekend workshops in 2008. The goal was to bring the top people from both groups together to see how the mass and volume capabilities of NASA's Ares V heavy lift launch vehicle could benefit the science community. Ares V is part of NASA's Constellation Program for resuming human exploration beyond low Earth orbit, starting with missions to the Moon. In the current mission scenario, Ares V launches a lunar lander into Earth orbit. A smaller Ares I rocket launches the Orion crew vehicle with up to four astronauts. Orion docks with the lander, attached to the Ares V Earth departure stage. The stage fires its engine to send the mated spacecraft to the Moon. Standing 360 feet high and weighing 7.4 million pounds, NASA's new heavy lifter will be bigger than the 1960s-era Saturn V. It can launch almost 60 percent more payload to translunar insertion together with the Ares I and 35 percent more mass to low Earth orbit than the Saturn V. This super-sized capability is, in short, designed to send more people to more places to do more things than the six Apollo missions.

Morris,Bruce↗

NASA NTRS2011

ARES I Upper Stage Subsystems Design and Development

From 2005 through early 2011, NASA conducted concept definition, design, and development of the Ares I launch vehicle. The Ares I was conceived to serve as a crew launch vehicle for beyond-low-Earth-orbit human space exploration missions as part of the Constellation Program Architecture. The vehicle was configured with a single shuttle-derived solid rocket booster first stage and a new liquid oxygen/liquid hydrogen upper stage, propelled by a single, newly developed J-2X engine. The Orion Crew Exploration Vehicle was to be mated to the forward end of the Ares I upper stage through an interface with fairings and a payload adapter. The vehicle design passed a Preliminary Design Review in August 2008, and was nearing the Critical Design Review when efforts were concluded as a result of the Constellation Program s cancellation. At NASA Glenn Research Center, four subsystems were developed for the Ares I upper stage. These were thrust vector control (TVC) for the J-2X, electrical power system (EPS), purge and hazardous gas (P&HG), and development flight instrumentation (DFI). The teams working each of these subsystems achieved 80 percent or greater design completion and extensive development testing. These efforts were extremely successful representing state-of-the-art technology and hardware advances necessary to achieve Ares I reliability, safety, availability, and performance requirements. This paper documents the designs, development test activity, and results.

Frate, David T.↗

NASA NTRS2011

Overview of Experimental Investigations for Ares I Launch Vehicle Development

Another concern for the vehicle during its design trajectory was the separation of the first stage solid rocket booster from the upper stage component after it had depleted its solid fuel propellant. There has been some concern about the interstage of the first stage from clearing the nozzle of the J2-X engine. A detailed separation aerodynamic wind tunnel investigation was conducted in the AEDC VKF Tunnel A to help to investigate the interaction aerodynamic effects5. A comparison of the separation plane details between the Ares I architecture and the Ares I-X demonstration flight architecture is shown in figure 12. The Ares I design requires a more complex separation sequence and requires better control in order to avoid contact with the nozzle of the upper stage engine. The interstage, which houses the J2-X engine for the Ares I vehicle, must be able to separate cleanly to avoid contact of the J2-X engine. There is only about approximately 18 inches of buffer inside the interstage on each size of the nozzle so this is a challenging controlled separation event. This complex experimental investigation required two separate Ares I models (upper stage and first stage with interstage attached) with independent strain gauge balances installed in each model. It also required the Captive Trajectory System (CTS) that was needed to precisely locate the components in space relative to each other to fill out the planned test matrix. The model setup in the AEDC VKF Tunnel A is shown in figure 13. The CTS remotely positioned the first stage at the required x, y, and z positions and was able to provide interactions within 0.2" of the upper stage. A sample of the axial force on the first stage booster is shown in figure 14. These results, as a function of separation distance between the two stages, are compared to pre-test CFD results. Since this is a very challenging, highly unsteady flow field for CFD to correctly model, the experimental results have been utilized by GN&C discipline to more accurately represent the interaction aerodynamics. In addition to the integrated forces and moments obtained from the test, flow visualization data was obtained from this test in the form of Schlieren photographs, as shown in figure 15, which show the shock structure and interaction effects after the two stages separate during flight. This separation test was crucial in the successful flight test of the Ares I-X vehicle and provided the GN&C discipline with the unpowered proximity aerodynamic effect for a separation of the Ares I vehicle.

Tomek, William G.↗

NASA NTRS2010

Lessons Learned in Building the Ares Projects

Since being established in 2005, the Ares Projects at Marshall Space Flight Center have been making steady progress designing, building, testing, and flying the next generation of exploration launch vehicles. Ares is committed to rebuilding crucial capabilities from the Apollo era that made the first human flights to the Moon possible, as well as incorporating the latest in computer technology and changes in management philosophy. One example of an Apollo-era practice has been giving NASA overall authority over vehicle integration activities, giving civil service engineers hands-on experience in developing rocket hardware. This knowledge and experience help make the agency a "smart buyer" of products and services. More modern practices have been added to the management tool belt to improve efficiency, cost effectiveness, and institutional knowledge, including knowledge management/capture to gain better insight into design and decision making; earned value management, where Ares won a NASA award for its practice and implementation; designing for operability; and Lean Six Sigma applications to identify and eliminate wasted time and effort. While it is important to learn technical lessons like how to fly and control unique rockets like the Ares I-X flight test vehicle, the Ares management team also has been learning important lessons about how to manage large, long-term projects.

Sumrall, John Phil↗

NASA NTRS1993

A Laboratory Model of a Hydrogen/Oxygen Engine for Combustion and Nozzle Studies

A small laboratory diagnostic thruster was developed to augment present low thrust chemical rocket optical and heat flux diagnostics at the NASA Lewis Research Center. The objective of this work was to evaluate approaches for the use of temperature and pressure sensors for the investigation of low thrust rocket flow fields. The nominal engine thrust was 110 N. Tests were performed at chamber pressures of about 255 kPa, 370 kPa, and 500 kPa with oxidizer to fuel mixture ratios between 4.0 and 8.0. Two gaseous hydrogen/gaseous oxygen injector designs were tested with 60 percent and 75 percent fuel film cooling. The thruster and instrumentation designs were proven to be effective via hot fire testing. The thruster diagnostics provided inner wall temperature and static pressure measurements which were compared to the thruster global performance data. For several operating conditions, the performance data exhibited unexpected trends which were correlated with changes in the axial wall temperature distribution. Azimuthal temperature distributions were found to be a function of operating conditions and hardware configuration. The static pressure profiles showed that no severe pressure gradients were present in the rocket. The results indicated that small differences in injector design can result in dramatically different thruster performance and wall temperature behavior, but that these injector effects may be overshadowed by operating at a high fuel film cooling rate.

Morren, Sybil Huang↗

NASA NTRS1976

Acoustic cavity technology for high performance injectors

The feasibility of damping more than one mode of rocket engine combustion instability by means of differently tuned acoustic cavities sharing a common entrance was shown. Analytical procedures and acoustic modeling techniques for predicting the stability behavior of acoustic cavity designs in hot firings were developed. Full scale testing of various common entrance, dual cavity configurations, and subscale testing for the purpose of obtaining motion pictures of the cavity entrance region, to aid in determining the mechanism of cavity damping were the two major aspects of the program.

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