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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 1,099 records · Page 61

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NASA NTRS1988

SSME 3-D Turnaround Duct flow analysis - CFD predictions

CFD analysis is presently employed to obtain an improved flowfield for an individual flowpath in the case of the Space Shuttle Main Engine's High Pressure Fuel Turbopump Turn-Around Duct (TAD), which conducts the flow exiting from the gas turbines into the fuel bowl. It is demonstrated that the application of CFD to TAD flow analysis, giving attention to the duct's configuration and to the number, shape, and alignment of the diffuser struts, can enhance understanding of flow physics and result in improved duct design and performance.

Brankovic, Andreja↗

NASA NTRS1988

3-D stator-rotor interaction of the SSME

The time-dependent stator-rotor interaction pattern of the Space Shuttle Main Engine's High-Pressure Fuel-Side Turbopump is presently studied by a multiple-zone solution algorithm, for both a two-dimensional case with 2:3 stator-rotor blade ratio and a three-dimensional case with a 1:1 ratio. A time-centered differencing scheme is used for temporal discretization, together with a sliding-grid multiple-zone solution method and an extended two-equation turbulence model with a wall function approach. The algorithm's accuracy is tested against experimental data.

Chen, Yen-Sen↗

NASA NTRS1989

Plating Patches On Heat-Exchanger Jackets

Permanent repairs made without welding. Technique used to repair nickel-alloy nozzle jacket of Space Shuttle main engine. Applicable to other metal heat-exchanger jackets with similar configurations. Does not require welding, brazing, soldering, or other operations involving high temperatures and consequent damage to surrounding areas. Portion of jacket around damaged area removed by grinding and polishing out to edges adjacent to tube/jacket braze bonds. Spaces between tubes filled with wax preventing contamination of spaces during subsequent plating.

Loureiro, Henry↗

NASA NTRS1989

Igniter Simulator

Report describes electronic circuitry that simulates electrical properties of igniter of Space Shuttle main engine. Circuit used to test software of engine controller, without having to fire real igniter or turn on engine. Circuit used in all igniter simulations and mimics operation of igniter more realistically than did previous versions.

Simon, Richard A.↗

NASA NTRS1989

Automated Heat-Flux-Calibration Facility

Computer control speeds operation of equipment and processing of measurements. New heat-flux-calibration facility developed at Lewis Research Center. Used for fast-transient heat-transfer testing, durability testing, and calibration of heat-flux gauges. Calibrations performed at constant or transient heat fluxes ranging from 1 to 6 MW/m2 and at temperatures ranging from 80 K to melting temperatures of most materials. Facility developed because there is need to build and calibrate very-small heat-flux gauges for Space Shuttle main engine (SSME).Includes lamp head attached to side of service module, an argon-gas-recirculation module, reflector, heat exchanger, and high-speed positioning system. This type of automated heat-flux calibration facility installed in industrial plants for onsite calibration of heat-flux gauges measuring fluxes of heat in advanced gas-turbine and rocket engines.

Liebert, Curt H.↗

NASA NTRS1988

Standardization of the carbon-phenolic materials and processes. Vol. 2: Test methods and specifications

Carbon-phenolic composite materials are used in the ablation process in the nozzles of the Space Shuttle Main Engine. The nozzle is lined with carbon cloth-phenolic resin composites. The extreme heat and erosion of the burning propellant are controlled by the carbon-phenolic composite by means of ablation, a heat and mass transfer process in which a large amount of heat is dissipated by sacrificailly removing material from a surface. Phenolic materials ablate with the initial formation of a char. The depth of the char is a function of the heat conduction coefficient of the composite. The char layer is a poor conductor so it protects the underlying phenolic composite from the high heat of the burning propellant. The nozzle component ablative liners (carbon cloth-phenolic resin composites) are tape wrapped, hydroclave and/or autoclave cured, machined and assembled. The tape consists of prepreg broadcloth. The materials flow sheet for the nozzle ablative liners is given. The prepreg is a three component system: phenolic resin, carbon cloth, and carbon filler. This is Volume 2 of the report, Test Methods and Specifications.

Hall, William B.↗

NASA NTRS1988

Flowfield visualization for SSME hot gas manifold

The objective of this research, as defined by NASA-Marshall Space Flight Center, was two-fold: (1) 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), and (2) to provide analytical support for SSME related numerical computational experiments, being performed by the Computational Fluid Dynamics staff in the Aerophysics Division of the Structures and Dynamics Laboratory at NASA-MSFC. Numerical results of HGM were calculations to complement both water flow visualization experiments and air flow visualization experiments and air experiments in two-duct geometries performed at NASA-MSFC and Rocketdyne. In addition, code modification and improvement efforts were to strengthen the CFD capabilities of NASA-MSFC for producing reliable predictions of flow environments within the SSME.

Roger, Robert P.↗

NASA NTRS1987

Mass flow meter using the triboelectric effect for measurement in cryogenics

The use of triboelectric charge to measure the mass flow rate of cryogens for the Space Shuttle Main Engine was investigated. Cross correlation of the triboelectric charge signals was used to determine the transit time of the cryogen between two sensor locations in a .75-in tube. The ring electrode sensors were mounted in a removable spool piece. Three spool pieces were constructed for delivery, each with a different design. One set of electronics for implementation of the cross correlation and flow calculation was constructed for delivery. Tests were made using a laboratory flow loop using liquid freon and transformer oil. The measured flow precision was 1 percent and the response was linear. The natural frequency distribution of the triboelectric signal was approximately 1/f. The sensor electrodes should have an axial length less than approximately one/tenth pipe diameter. The electrode spacing should be less than approximately one pipe diameter. Tests using liquid nitrogen demonstrated poor tribo-signal to noise ratio. Most of the noise was microphonic and common to both electrode systems. The common noise rejection facility of the correlator was successful in compensating for this noise but the signal was too small to enable reliable demonstration of the technique in liquid nitrogen.

Bernatowicz, Henry↗

NASA NTRS1988

SSME LOX post flow analyses/fluid structure interaction

Test firings of the Space Shuttle Main Engine (SSME) over the course of its development have resulted in several catastrophic failures. Some of these failures were due to breakage of the LOX posts that feed liquid oxygen into the main injector head of the engine. The objective was to perform a computational fluid flow analysis of a simplified SSME LOX post array using an existing viscous Navier-Stokes flow solver. A two-dimensional analysis was to be made. In addition, a finite element theory for treating the fluid/structure interaction between the posts and the hot gas environment was to be developed. The methodology used in computing the flow field through the LOX post array is described. Results are presented and discussed.

Source record↗

NASA NTRS1989

Heat flux measurements

A new automated, computer controlled heat flux measurement facility is described. Continuous transient and steady-state surface heat flux values varying from about 0.3 to 6 MW/sq m over a temperature range of 100 to 1200 K can be obtained in the facility. An application of this facility is the development of heat flux gauges for continuous fast transient surface heat flux measurement on turbine blades operating in space shuttle main engine turbopumps. The facility is useful for durability testing at fast temperature transients.

Liebert, Curt H.↗

NASA NTRS1988

Dynamic analysis of nonlinear rotor-housing systems

Nonlinear analysis methods are developed which will enable the reliable prediction of the dynamic behavior of the space shuttle main engine (SSME) turbopumps in the presence of bearing clearances and other local nonlinearities. A computationally efficient convolution method, based on discretized Duhamel and transition matrix integral formulations, is developed for the transient analysis. In the formulation, the coupling forces due to the nonlinearities are treated as external forces acting on the coupled subsystems. Iteration is utilized to determine their magnitudes at each time increment. The method is applied to a nonlinear generic model of the high pressure oxygen turbopump (HPOTP). As compared to the fourth order Runge-Kutta numerical integration methods, the convolution approach proved to be more accurate and more highly efficient. For determining the nonlinear, steady-state periodic responses, an incremental harmonic balance method was also developed. The method was successfully used to determine dominantly harmonic and subharmonic responses fo the HPOTP generic model with bearing clearances. A reduction method similar to the impedance formulation utilized with linear systems is used to reduce the housing-rotor models to their coordinates at the bearing clearances. Recommendations are included for further development of the method, for extending the analysis to aperiodic and chaotic regimes and for conducting critical parameteric studies of the nonlinear response of the current SSME turbopumps.

Noah, Sherif T.↗

NASA NTRS1988

Duct flow nonuniformities: Effect of struts in SSME HGM 2+

This study consists of an analysis of flow through the Space Shuttle Main Engine (SSME) Hot Gas Manifold (HGM) for the purpose of understanding and quantifying the flow environment and, in particular, the flow through a region of structural supports located between the inner and outer walls of the HGM. The primary task of the study, as defined by NASA-MSFC, is to assess and develop the computational capability for analyzing detailed three-dimensional flow through the HGM support strut region to be incorporated into a full fuelside HGM analysis. Secondarily, computed results are to be compared with available experimental results.

Burke, Roger↗

NASA NTRS1989

High performance alloy electroforming

Electroformed copper and nickel are used in structural applications for advanced propellant combustion chambers. An improved process has been developed by Bell Aerospace Textron, Inc. wherein electroformed nickel-manganese alloy has demonstrated superior mechanical and thermal stability when compared to previously reported deposits from known nickel plating processes. Solution chemistry and parametric operating procedures are now established and material property data is established for deposition of thick, large complex shapes such as the Space Shuttle Main Engine. The critical operating variables are those governing the ratio of codeposited nickel and manganese. The deposition uniformity which in turn affects the manganese concentration distribution is affected by solution resistance and geometric effects as well as solution agitation. The manganese concentration in the deposit must be between 2000 and 3000 ppm for optimum physical properties to be realized. The study also includes data regarding deposition procedures for achieving excellent bond strength at an interface with copper, nickel-manganese or INCONEL 718. Applications for this electroformed material include fabrication of complex or re-entry shapes which would be difficult or impossible to form from high strength alloys such as INCONEL 718.

Malone, G. A.↗

NASA NTRS1989

Turbomachinery aeroelasticity at NASA Lewis Research Center

The turbomachinery aeroelastic effort is focused on unstalled and stalled flutter, forced response, and whirl flutter of both single rotation and counter rotation propfans. It also includes forced response of the Space Shuttle Main Engine (SSME) turbopump blades. Because of certain unique features of propfans and the SSME turbopump blades, it is not possible to directly use the existing aeroelastic technology of conventional propellers, turbofans or helicopters. Therefore, reliable aeroelastic stability and response analysis methods for these propulsion systems must be developed. The development of these methods for propfans requires specific basic technology disciplines, such as 2-D and 3-D steady and unsteady aerodynamic theories in subsonic, transonic and supersonic flow regimes; modeling of composite blades; geometric nonlinear effects; and passive and active control of flutter and response. These methods are incorporated in a computer program, ASTROP. The program has flexibility such that new and future models in basic disciplines can be easily implemented.

Kaza, Krishna Rao V.↗

NASA NTRS1988

NESSUS (Numerical Evaluation of Stochastic Structures Under Stress)/EXPERT: Bridging the gap between artificial intelligence and FORTRAN

The development of a probabilistic structural analysis methodology (PSAM) is described. In the near-term, the methodology will be applied to designing critical components of the next generation space shuttle main engine. In the long-term, PSAM will be applied very broadly, providing designers with a new technology for more effective design of structures whose character and performance are significantly affected by random variables. The software under development to implement the ideas developed in PSAM resembles, in many ways, conventional deterministic structural analysis code. However, several additional capabilities regarding the probabilistic analysis makes the input data requirements and the resulting output even more complex. As a result, an intelligent front- and back-end to the code is being developed to assist the design engineer in providing the input data in a correct and appropriate manner. The type of knowledge that this entails is, in general, heuristically-based, allowing the fairly well-understood technology of production rules to apply with little difficulty. However, the PSAM code, called NESSUS, is written in FORTRAN-77 and runs on a DEC VAX. Thus, the associated expert system, called NESSUS/EXPERT, must run on a DEC VAX as well, and integrate effectively and efficiently with the existing FORTRAN code. This paper discusses the process undergone to select a suitable tool, identify an appropriate division between the functions that should be performed in FORTRAN and those that should be performed by production rules, and how integration of the conventional and AI technologies was achieved.

Fink, Pamela K.↗

NASA NTRS1989

Space shuttle propulsion estimation development verification, volume 1

The results of the Propulsion Estimation Development Verification are summarized. A computer program developed under a previous contract (NAS8-35324) was modified to include improved models for the Solid Rocket Booster (SRB) internal ballistics, the Space Shuttle Main Engine (SSME) power coefficient model, the vehicle dynamics using quaternions, and an improved Kalman filter algorithm based on the U-D factorized algorithm. As additional output, the estimated propulsion performances, for each device are computed with the associated 1-sigma bounds. The outputs of the estimation program are provided in graphical plots. An additional effort was expended to examine the use of the estimation approach to evaluate single engine test data. In addition to the propulsion estimation program PFILTER, a program was developed to produce a best estimate of trajectory (BET). The program LFILTER, also uses the U-D factorized algorithm form of the Kalman filter as in the propulsion estimation program PFILTER. The necessary definitions and equations explaining the Kalman filtering approach for the PFILTER program, the models used for this application for dynamics and measurements, program description, and program operation are presented.

Rogers, Robert M.↗

NASA NTRS1989

Advanced single crystal for SSME turbopumps

The objective of this program was to evaluate the influence of high thermal gradient casting, hot isostatic pressing (HIP) and alternate heat treatments on the microstructure and mechanical properties of a single crystal nickel base superalloy. The alloy chosen for the study was PWA 1480, a well characterized, commercial alloy which had previously been chosen as a candidate for the Space Shuttle Main Engine high pressure turbopump turbine blades. Microstructural characterization evaluated the influence of casting thermal gradient on dendrite arm spacing, casting porosity distribution and alloy homogeneity. Hot isostatic pressing was evaluated as a means of eliminating porosity as a preferred fatigue crack initiation site. The alternate heat treatment was chosen to improve hydrogen environment embrittlement resistance and for potential fatigue life improvement. Mechanical property evaluation was aimed primarily at determining improvements in low cycle and high cycle fatigue life due to the advanced processing methods. Statistically significant numbers of tests were conducted to quantitatively demonstrate life differences. High thermal gradient casting improves as-cast homogeneity, which facilitates solution heat treatment of PWA 1480 and provides a decrease in internal pore size, leading to increases in low cycle and high cycle fatigue lives.

Fritzemeier, L. G.↗

NASA NTRS1988

A performance/loss evaluation of SSME HPFTP turbine

An evaluation of component losses of the High Pressure Fuel Turbopump (HPFTP) in the Space Shuttle Main Engine (SSME) is performed using a mean-line prediction method. This is accompanied with an extensive review of loss correlations in the literature. The present prediction uses an existing gas path velocity triangle, real LH2 and H2O gas properties and loss correlations selected from the literature. The significant losses incurred in the HPFTP turbine include profile loss, secondary loss, and tip clearance loss. Results obtained from the present prediction are compared to those calculated from a quasi-three dimensional numerical analysis. Except for the clearance loss, the present loss coefficients are in general higher than their counterparts from the quasi-three dimensional analysis. The fact that the mean-line velocity data being unable to represent actual flow fields near the hub and the tip regions is largely responsible for the uncertainty involved in the present method. On the other hand, due mainly to the ad-hoc nature of the studies involved, the correlations currently available in the literature may not be suitable for accurate loss prediction of the particular rocket turbine in the SSME HPFTP. Further studies particularly in the areas of tip clearance loff, coolant loss, secondary loss, and their interactions are desirable. Fundamental phenomena concerning flow unsteadiness in wake shedding and turbulence are also important.

Chyu, Mingking K.↗