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NASA NTRS2003

Space Shuttle Main Engine Implications for the Abort-to-Orbit Off-the-Pad Study

In 2001, the Space Shuttle Main Engine (SSME) project office was contacted by the Space Shuttle Ascent Guidance, Navigation, and Control group to provide the engine perspective for an Abort-to-Orbit (ATO) study. The purpose of the AT0 Off-the-Pad study was to determine the feasibility of eliminating the Return to Launch Site and Transatlantic abort modes by using a five-segment solid rocket booster and throttling the remaining SSMEs to a higher power level. This would enable all abort modes to be Abort-to-Orbit. The SSME project office at Marshall Space Flight Center collaborated with MSFC's Space Transportation Directorate and Rocketdyne Propulsion and Power to provide the AT0 Off-the-Pad study with the analysis required. Power levels at 109%, 1 11% and 1 13% of rated power level were studied as well as mixture ratio decreases down to 5.85. SSME was to evaluate and define the technical and programmatic impacts to certify the SSME to these abort power levels. The SSME systems analysis group performed a steady state analysis using the SSME power balance model to determine if there were any technical issues associated with higher power level, low mixture ratio operation. Based on each power level/mixture ratio combination, an engine certification plan was created and a preliminary probabilistic risk assessment was performed. The results showed favorable results for higher power 1evel/lower mixture ratio SSME operation. In nearly all performance and redline parameters, the traded engine operation was encompassed by nominal engine performance of a prior engine configuration.

Schoffstoll, Dayna L.↗

NASA NTRS1946

Investigation of Operating Characteristics of an Engine Equipped with Modifications to Eliminate Fuel-Evaporation Icing

Two modified fuel-injection systems, a drilled-inducer type and a spinner type, that prevent serious fuel-evaporation icing were installed on a V-type, liquid-cooled aircraft engine and a preliminary investigation was conducted to determine the effect on engine operating characteristics. The spinner system was also ground - and flight tested on a twin-engine fighter airplane. Flight measurements of cylinder-head temperature over a range of fuel-air ratios and engine power conditions were made at an altitude of approximately 10,000 feet. Starting and accelerating of the engine on the ground were unaffected by the fuel-injection modifications. During the flight investigation, no appreciable variation occurred between the maximum and minimum cylinder-head temperature with the standard and modified system for the same power condition and no irregularity of mixture distribution could be detected throughout the power range of the engine. Normal mixture distribution was also indicated by a similar response of cylinder-head temperature for variations of fuel-air ratio at manifold pressures of 25 and 35 inches of mercury absolute. Both modified fuel-injection systems required less fuel-nozzle pressure than the standard system to obtain the desired fuel-air ratio for given air-flow condition.

Mulholland, Donald R.↗

NASA NTRS2004

Turnaround Time Modeling for Conceptual Rocket Engines

Recent years have brought about a paradigm shift within NASA and the Space Launch Community regarding the performance of conceptual design. Reliability, maintainability, supportability, and operability are no longer effects of design; they have moved to the forefront and are affecting design. A primary focus of this shift has been a planned decrease in vehicle turnaround time. Potentials for instituting this decrease include attacking the issues of removing, refurbishing, and replacing the engines after each flight. less, it is important to understand the operational affects of an engine on turnaround time, ground support personnel and equipment. One tool for visualizing this relationship involves the creation of a Discrete Event Simulation (DES). A DES model can be used to run a series of trade studies to determine if the engine is meeting its requirements, and, if not, what can be altered to bring it into compliance. Using DES, it is possible to look at the ways in which labor requirements, parallel maintenance versus serial maintenance, and maintenance scheduling affect the overall turnaround time. A detailed DES model of the Space Shuttle Main Engines (SSME) has been developed. Trades may be performed using the SSME Processing Model to see where maintenance bottlenecks occur, what the benefits (if any) are of increasing the numbers of personnel, or the number and location of facilities, in addition to trades previously mentioned, all with the goal of optimizing the operational turnaround time and minimizing operational cost. The SSME Processing Model was developed in such a way that it can easily be used as a foundation for developing DES models of other operational or developmental reusable engines. Performing a DES on a developmental engine during the conceptual phase makes it easier to affect the design and make changes to bring about a decrease in turnaround time and costs.

Nix, Michael↗

NASA NTRS1998

Hyper-X Engine Design and Ground Test Program

The Hyper-X Program, NASA's focused hypersonic technology program jointly run by NASA Langley and Dryden, is designed to move hypersonic, air-breathing vehicle technology from the laboratory environment to the flight environment, the last stage preceding prototype development. The Hyper-X research vehicle will provide the first ever opportunity to obtain data on an airframe integrated supersonic combustion ramjet propulsion system in flight, providing the first flight validation of wind tunnel, numerical and analytical methods used for design of these vehicles. A substantial portion of the integrated vehicle/engine flowpath development, engine systems verification and validation and flight test risk reduction efforts are experimentally based, including vehicle aeropropulsive force and moment database generation for flight control law development, and integrated vehicle/engine performance validation. The Mach 7 engine flowpath development tests have been completed, and effort is now shifting to engine controls, systems and performance verification and validation tests, as well as, additional flight test risk reduction tests. The engine wind tunnel tests required for these efforts range from tests of partial width engines in both small and large scramjet test facilities, to tests of the full flight engine on a vehicle simulator and tests of a complete flight vehicle in the Langley 8-Ft. High Temperature Tunnel. These tests will begin in the summer of 1998 and continue through 1999. The first flight test is planned for early 2000.

Voland, R. T.↗

NASA NTRS1947

Preliminary Results of an Altitude-Wind-Tunnel Investigation of a TG-100A Gas Turbine-Propeller Engine: Combustion-Chamber Characteristics - V

An investigation to determine the performance and operational characteristics of the TG-1OOA gas turbine-propeller engine was conducted in the Cleveland altitude wind tunnel. As part of this investigation, the combustion-chamber performance was determined at pressure altitudes from 5000 to 35,000 feet, compressor-inlet rm-pressure ratios of 1.00 and 1.09, and engine speeds from 8000 to 13,000 rpm. Combustion-chamber performance is presented as a function of corrected engine speed and.correcte& horsepower. For the range of corrected engine speeds investigated, over-all total-pressure-loss ratio, cycle efficiency, ana the frac%ional loss in cycle efficiency resulting from pressure losses in the combustion chambers were unaffected by a change in altitude or compressor-inlet ram-pressure ratio. The scatter of combustion- efficiency data tended to obscure any effect of altitude or ram-pressure ratio. For the range of corrected horse-powers investigated, the total-pressure-loss ratio an& the fractional loss in cycle efficiency resulting from pressure losses in the combustion chambers decreased with an increase in corrected horsepower at a constant corrected engine speed. The combustion efficiency remained constant for the range of corrected horse-powers investigated at all corrected engine speeds.

Gensenheyner, Robert M.↗

NASA NTRS1948

Altitude-Wind-Tunnel Investigation of a 3000-Pound-Thrust Axial-Flow Turbojet Engine: Performance and Windmilling Drag Characteristics - Part 5

An investigation has been conducted in the NACA Cleveland altitude wind tunnel to evaluate the performance and windmilling drag characteristics of an original and a modified turbojet engine of the same type. Data have been obtained at simulated altitudes from 5000 to 45,000 feet, simulated flight Mach numbers from 0.09 to 1.08, and engine speeds from 4000 to 12,500 rpm. Engine performance data are presented for both engines to show the effects of altitude at a flight Mach number of 0.25 and of flight Mach number at an altitude of 25,000 feet. Performance of the original and modified engines is compared for a range of simulated flight conditions. The performance data are generalized to show the applicability of methods used to estimate performance at any altitude from data obtained at a given altitude. Engine-windmilling-speed and windmilling-drag data are presented for a range of simulated flight conditions.

Meyer, Carl L.↗

NASA NTRS1947

Preliminary Results of Altitude-Wind-Tunnel Investigation of X24C-4B Turbojet Engine. IV - Performance of Modified Compressor: Performance of Modified Compressor - Part 4

The performance of the 11-stage axial-flow compressor, modified to improve the compressor-outlet velocity, in a revised X24C-4B turbojet engine is presented and compared with the performance of the compressor in the original engine. Performance data were obtained from an investigation of the revised engine in the MACA Cleveland altitude wind tunnel. Compressor performance data were obtained for engine operation with four exhaust nozzles of different outlet area at simulated altitudes from 15,OOO to 45,000 feet, simulated flight Mach numbers from 0.24 to 1.07, and engine speeds from 4000 to 12,500 rpm. The data cover a range of corrected engine speeds from 4100 to 13,500 rpm, which correspond to compressor Mach numbers from 0.30 to 1.00.

Thorman, H. Carl↗

NASA NTRS1947

Preliminary Results of Altitude-Wind-Tunnel Investigation of X34C-4B Turbojet Engine. III - Compressor Performance: Compressor Performance - 3

The performance of the 11-stage axial-flow compressor in the X24C-4B turbojet engine was analyzed on the basis of results obtained from an investigation of the complete engine in the NACA Cleveland altitude wind tunnel. The engine was operated with four, exhaust nozzles of different outlet area over a range of engine speeds from 6000 to 12,500 rpm, corrected engine speeds from approximately 6100 to 13,600 rpm, and compressor Mach numbers from 0.45 to 1.00. Data are presented for engine operation over a range of simulated altitudes from 15,000 to 45,000 feet and simulated flight Mach numbers from 0.24 to 1.08.

Dupree, David T.↗

NASA NTRS2005

Lifing of Engine Components

The successful development of advanced aerospace engines depends greatly on the capabilities of high performance materials and structures. Advanced materials, such as nickel based single crystal alloys, metal foam, advanced copper alloys, and ceramics matrix composites, have been engineered to provide higher engine temperature and stress capabilities. Thermal barrier coatings have been developed to improve component durability and fuel efficiency, by reducing the substrate hot wall metal temperature and protecting against oxidation and blanching. However, these coatings are prone to oxidation and delamination failures. In order to implement the use of these materials in advanced engines, it is necessary to understand and model the evolution of damage of the metal substrate as well as the coating under actual engine conditions. The models and the understanding of material behavior are utilized in the development of a life prediction methodology for hot section components. The research activities were focused on determining the stress and strain fields in an engine environment under combined thermo-mechanical loads to develop life prediction methodologies consistent with the observed damage formation of the coating and the substrates.

Source record↗

NASA NTRS2005

Overview of NASA MSFC IEC Federated Engineering Collaboration Capability

The MSFC IEC federated engineering framework is currently developing a single collaborative engineering framework across independent NASA centers. The federated approach allows NASA centers the ability to maintain diversity and uniqueness, while providing interoperability. These systems are integrated together in a federated framework without compromising individual center capabilities. MSFC IEC's Federation Framework will have a direct affect on how engineering data is managed across the Agency. The approach is directly attributed in response to the Columbia Accident Investigation Board (CAB) finding F7.4-11 which states the Space Shuttle Program has a wealth of data sucked away in multiple databases without a convenient way to integrate and use the data for management, engineering, or safety decisions. IEC s federated capability is further supported by OneNASA recommendation 6 that identifies the need to enhance cross-Agency collaboration by putting in place common engineering and collaborative tools and databases, processes, and knowledge-sharing structures. MSFC's IEC Federated Framework is loosely connected to other engineering applications that can provide users with the integration needed to achieve an Agency view of the entire product definition and development process, while allowing work to be distributed across NASA Centers and contractors. The IEC DDMS federation framework eliminates the need to develop a single, enterprise-wide data model, where the goal of having a common data model shared between NASA centers and contractors is very difficult to achieve.

Moushon, Brian↗

NASA NTRS1998

F100 Engine Emissions Tested in NASA Lewis' Propulsion Systems Laboratory

Recent advances in atmospheric sciences have shown that the chemical composition of the entire atmosphere of the planet (gases and airborne particles) has been changed due to human activity and that these changes have changed the heat balance of the planet. National Research Council findings indicate that anthropogenic aerosols1 reduce the amount of solar radiation reaching the Earth's surface. Atmospheric global models suggest that sulfate aerosols change the energy balance of the Northern Hemisphere as much as anthropogenic greenhouse gases have. In response to these findings, NASA initiated the Atmospheric Effects of Aviation Project (AEAP) to advance the research needed to define present and future aircraft emissions and their effects on the Earth's atmosphere. Although the importance of aerosols and their precursors is now well recognized, the characterization of current subsonic engines for these emissions is far from complete. Furthermore, since the relationship of engine operating parameters to aerosol emissions is not known, extrapolation to untested and unbuilt engines necessarily remains highly uncertain. Tests in 1997-an engine test at the NASA Lewis Research Center and the corresponding flight measurement test at the NASA Langley Research Center-attempted to address both issues by measuring emissions when fuels containing different levels of sulfur were burned. Measurement systems from four research groups were involved in the Lewis engine test: A Lewis gas analyzer suite to measure the concentration of gaseous species 1. including NO, NOx, CO, CO2, O2, THC, and SO2 as well as the smoke number; 2. A University of Missouri-Rolla Mobile Aerosol Sampling System to measure aerosol and particulate properties including the total concentration, size distribution, volatility, and hydration property; 3. An Air Force Research Laboratory Chemical Ionization Mass Spectrometer to measure the concentration of SO2 and SO3/H2SO4; and 4. An Aerodyne Research Inc. Tunable Diode Laser System to measure the concentrations of SO2, SO3, NO, NO2, CO2, and H2O. By September 1997, an F100 engine operating at several power levels at sea level and up to six simulated altitudes had been tested with commercial jet fuels with three levels of sulfur content and one military jet fuel. The data are being vigorously analyzed. A complete report is anticipated for the 1998 Atmospheric Effects of Aviation Project Annual Conference.

Wey, Chowen C.↗

NASA NTRS1997

More-Electric Gas Turbine Engines

A new NASA Lewis Research Center and U.S. Army Research Laboratory (ARL) thrust, the more-electric commercial engine, is creating significant interest in industry. This engine would have an integral starter-generator on the gas generator shaft and would be fully supported by magnetic bearings. The NASA/Army emphasis is on a high-temperature magnetic bearing for future gas turbine engines. Magnetic bearings could increase the reliability and reduce the weight of such engines by eliminating the lubrication system. They could also increase the DN (diameter of the bearing times the rpm) limit on engine speed and allow active vibration cancellation systems to be used, resulting in a more efficient, more-electric engine.

Kascak, Albert F.↗

NASA NTRS2005

Rocket Engine Nozzle Side Load Transient Analysis Methodology: A Practical Approach

During the development stage, in order to design/to size the rocket engine components and to reduce the risks, the local dynamic environments as well as dynamic interface loads must be defined. There are two kinds of dynamic environment, i.e. shock transients and steady-state random and sinusoidal vibration environments. Usually, the steady-state random and sinusoidal vibration environments are scalable, but the shock environments are not scalable. In other words, based on similarities only random vibration environments can be defined for a new engine. The methodology covered in this paper provides a way to predict the shock environments and the dynamic loads for new engine systems and new engine components in the early stage of new engine development or engine nozzle modifications.

Shi, John J.↗

NASA NTRS2004

Thermodynamic Modeling of a Solid Oxide Fuel Cell to Couple with an Existing Gas Turbine Engine Model

The Controls and Dynamics Technology Branch at NASA Glenn Research Center are interested in combining a solid oxide fuel cell (SOFC) to operate in conjunction with a gas turbine engine. A detailed engine model currently exists in the Matlab/Simulink environment. The idea is to incorporate a SOFC model within the turbine engine simulation and observe the hybrid system's performance. The fuel cell will be heated to its appropriate operating condition by the engine s combustor. Once the fuel cell is operating at its steady-state temperature, the gas burner will back down slowly until the engine is fully operating on the hot gases exhausted from the SOFC. The SOFC code is based on a steady-state model developed by The U.S. Department of Energy (DOE). In its current form, the DOE SOFC model exists in Microsoft Excel and uses Visual Basics to create an I-V (current-voltage) profile. For the project's application, the main issue with this model is that the gas path flow and fuel flow temperatures are used as input parameters instead of outputs. The objective is to create a SOFC model based on the DOE model that inputs the fuel cells flow rates and outputs temperature of the flow streams; therefore, creating a temperature profile as a function of fuel flow rate. This will be done by applying the First Law of Thermodynamics for a flow system to the fuel cell. Validation of this model will be done in two procedures. First, for a given flow rate the exit stream temperature will be calculated and compared to DOE SOFC temperature as a point comparison. Next, an I-V curve and temperature curve will be generated where the I-V curve will be compared with the DOE SOFC I-V curve. Matching I-V curves will suggest validation of the temperature curve because voltage is a function of temperature. Once the temperature profile is created and validated, the model will then be placed into the turbine engine simulation for system analysis.

Brinson, Thomas E.↗

NASA NTRS2004

Critical Low-Noise Technologies Being Developed for Engine Noise Reduction Systems Subproject

NASA's previous Advanced Subsonic Technology (AST) Noise Reduction Program delivered the initial technologies for meeting a 10-year goal of a 10-dB reduction in total aircraft system noise. Technology Readiness Levels achieved for the engine-noise-reduction technologies ranged from 4 (rig scale) to 6 (engine demonstration). The current Quiet Aircraft Technology (QAT) project is building on those AST accomplishments to achieve the additional noise reduction needed to meet the Aerospace Technology Enterprise's 10-year goal, again validated through a combination of laboratory rig and engine demonstration tests. In order to meet the Aerospace Technology Enterprise goal for future aircraft of a 50- reduction in the perceived noise level, reductions of 4 dB are needed in both fan and jet noise. The primary objectives of the Engine Noise Reduction Systems (ENRS) subproject are, therefore, to develop technologies to reduce both fan and jet noise by 4 dB, to demonstrate these technologies in engine tests, and to develop and experimentally validate Computational Aero Acoustics (CAA) computer codes that will improve our ability to predict engine noise.

Grady, Joseph E.↗

NASA NTRS2000

Acoustics and Thrust of Separate Flow Exhaust Nozzles With Mixing Devices Investigated for High Bypass Ratio Engines

Typical installed separate-flow exhaust nozzle system. The jet noise from modern turbofan engines is a major contributor to the overall noise from commercial aircraft. Many of these engines use separate nozzles for exhausting core and fan streams. As a part of NASA s Advanced Subsonic Technology (AST) program, the NASA Glenn Research Center at Lewis Field led an experimental investigation using model-scale nozzles in Glenn s Aero-Acoustic Propulsion Laboratory. The goal of the investigation was to develop technology for reducing the jet noise by 3 EPNdB. Teams of engineers from Glenn, the NASA Langley Research Center, Pratt & Whitney, United Technologies Research Corporation, the Boeing Company, GE Aircraft Engines, Allison Engine Company, and Aero Systems Engineering contributed to the planning and implementation of the test.

Saiyed, Naseem H.↗

NASA NTRS2004

Turbofan Engine Simulated in a Graphical Simulation Environment

Recently, there has been an increase in the development of intelligent engine technology with advanced active component control. The computer engine models used in these control studies are component-level models (CLM), models that link individual component models of state space and nonlinear algebraic equations, written in a computer language such as Fortran. The difficulty faced in performing control studies on Fortran-based models is that Fortran is not supported with control design and analysis tools, so there is no means for implementing real-time control. It is desirable to have a simulation environment that is straightforward, has modular graphical components, and allows easy access to health, control, and engine parameters through a graphical user interface. Such a tool should also provide the ability to convert a control design into real-time code, helping to make it an extremely powerful tool in control and diagnostic system development. Simulation time management is shown: Mach number versus time, power level angle versus time, altitude versus time, ambient temperature change versus time, afterburner fuel flow versus time, controller and actuator dynamics, collect initial conditions, CAD output, and component-level model: CLM sensor, CAD input, and model output. The Controls and Dynamics Technologies Branch at the NASA Glenn Research Center has developed and demonstrated a flexible, generic turbofan engine simulation platform that can meet these objectives, known as the Modular Aero-Propulsion System Simulation (MAPSS). MAPSS is a Simulink-based implementation of a Fortran-based, modern high pressure ratio, dual-spool, low-bypass, military-type variable-cycle engine with a digital controller. Simulink (The Mathworks, Natick, MA) is a computer-aided control design and simulation package allows the graphical representation of dynamic systems in a block diagram form. MAPSS is a nonlinear, non-real-time system composed of controller and actuator dynamics (CAD) and component-level model (CLM) modules. The controller in the CAD module emulates the functionality of a digital controller, which has a typical update rate of 50 Hz. The CLM module simulates the dynamics of the engine components and uses an update rate of 2500 Hz, which is needed to iterate to balance mass and energy among system components. The actuators in the CAD module use the same sampling rate as those in the CLM. Two graphs of normalized spool speed versus time in seconds and one graph of normalized average metal temperature versus time in seconds is shown. MAPSS was validated via open-loop and closed-loop comparisons with the Fortran simulation. The preceding plots show the normalized results of a closed-loop comparison looking at three states of the model: low-pressure spool speed, high-pressure spool speed, and the average metal temperature measured from the combustor to the high-pressure turbine. In steady state, the error between the simulations is less than 1 percent. During a transient, the difference between the simulations is due to a correction in MAPSS that prevents the gas flow in the bypass duct inlet from flowing forward instead of toward the aft end, which occurs in the Fortran simulation. A comparison between MAPSS and the Fortran model of the bypass duct inlet flow for power lever angles greater than 35 degrees is shown.

Parker, Khary I.↗

NASA NTRS2005

Integrated System-Level Optimization for Concurrent Engineering With Parametric Subsystem Modeling

The introduction of concurrent design practices to the aerospace industry has greatly increased the productivity of engineers and teams during design sessions as demonstrated by JPL's Team X. Simultaneously, advances in computing power have given rise to a host of potent numerical optimization methods capable of solving complex multidisciplinary optimization problems containing hundreds of variables, constraints, and governing equations. Unfortunately, such methods are tedious to set up and require significant amounts of time and processor power to execute, thus making them unsuitable for rapid concurrent engineering use. This paper proposes a framework for Integration of System-Level Optimization with Concurrent Engineering (ISLOCE). It uses parametric neural-network approximations of the subsystem models. These approximations are then linked to a system-level optimizer that is capable of reaching a solution quickly due to the reduced complexity of the approximations. The integration structure is described in detail and applied to the multiobjective design of a simplified Space Shuttle external fuel tank model. Further, a comparison is made between the new framework and traditional concurrent engineering (without system optimization) through an experimental trial with two groups of engineers. Each method is evaluated in terms of optimizer accuracy, time to solution, and ease of use. The results suggest that system-level optimization, running as a background process during integrated concurrent engineering sessions, is potentially advantageous as long as it is judiciously implemented.

Schuman, Todd↗