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NASA NTRS2014

Validation Ice Crystal Icing Engine Test in the Propulsion Systems Laboratory at NASA Glenn Research Center

The Propulsion Systems Laboratory (PSL) is an existing altitude simulation jet engine test facility located at NASA Glenn Research Center in Clevleand, OH. It was modified in 2012 with the integration of an ice crystal cloud generation system. This paper documents the inaugural ice crystal cloud test in PSLthe first ever full scale, high altitude ice crystal cloud turbofan engine test to be conducted in a ground based facility. The test article was a Lycoming ALF502-R5 high bypass turbofan engine, serial number LF01. The objectives of the test were to validate the PSL ice crystal cloud calibration and engine testing methodologies by demonstrating the capability to calibrate and duplicate known flight test events that occurred on the same LF01 engine and to generate engine data to support fundamental and computational research to investigate and better understand the physics of ice crystal icing in a turbofan engine environment while duplicating known revenue service events and conducting test points while varying facility and engine parameters. During PSL calibration testing it was discovered than heated probes installed through tunnel sidewalls experienced ice buildup aft of their location due to ice crystals impinging upon them, melting and running back. Filtered city water was used in the cloud generation nozzle system to provide ice crystal nucleation sites. This resulted in mineralization forming on flow path hardware that led to a chronic degradation of performance during the month long test. Lacking internal flow path cameras, the response of thermocouples along the flow path was interpreted as ice building up. Using this interpretation, a strong correlation between total water content (TWC) and a weaker correlation between median volumetric diameter (MVD) of the ice crystal cloud and the rate of ice buildup along the instrumented flow path was identified. For this test article the engine anti-ice system was required to be turned on before ice crystal icing would occur. The ice crystal icing event, an uncommanded reduction in thrust, was able to be turned on and off by manipulating cloud TWC. A flight test point where no ice crystal icing event occurred was also duplicated in PSL. Physics based computational tools were successfully used to predict tunnel settings to induce ice buildup along the low pressure compression system flow path for several test points at incrementally lower altitudes, demonstrating that development of ice crystal icing scaling laws is potentially feasible. Analysis of PSL test data showed that uncommanded reduction in thrust occurs during ice crystal cloud on operation prior to fan speed reduction. This supports previous findings that the reduction of thrust for this test article is due to ice buildup leading to a restricted airflow from either physical or aerodynamic blockage in the engine core flow path.

Ice Crystal Icing↗

NASA NTRS2014

Validation Ice Crystal Icing Engine Test in the Propulsion Systems Laboratory at NASA Glenn Research Center

The Propulsion Systems Laboratory (PSL) is an existing altitude simulation jet engine test facility located at NASA Glenn Research Center in Cleveland, OH. It was modified in 2012 with the integration of an ice crystal cloud generation system. This paper documents the inaugural ice crystal cloud test in PSL--the first ever full scale, high altitude ice crystal cloud turbofan engine test to be conducted in a ground based facility. The test article was a Lycoming ALF502-R5 high bypass turbofan engine, serial number LF01. The objectives of the test were to validate the PSL ice crystal cloud calibration and engine testing methodologies by demonstrating the capability to calibrate and duplicate known flight test events that occurred on the same LF01 engine and to generate engine data to support fundamental and computational research to investigate and better understand the physics of ice crystal icing in a turbofan engine environment while duplicating known revenue service events and conducting test points while varying facility and engine parameters. During PSL calibration testing it was discovered than heated probes installed through tunnel sidewalls experienced ice buildup aft of their location due to ice crystals impinging upon them, melting and running back. Filtered city water was used in the cloud generation nozzle system to provide ice crystal nucleation sites. This resulted in mineralization forming on flow path hardware that led to a chronic degradation of performance during the month long test. Lacking internal flow path cameras, the response of thermocouples along the flow path was interpreted as ice building up. Using this interpretation, a strong correlation between total water content (TWC) and a weaker correlation between median volumetric diameter (MVD) of the ice crystal cloud and the rate of ice buildup along the instrumented flow path was identified. For this test article the engine anti-ice system was required to be turned on before ice crystal icing would occur. The ice crystal icing event, an uncommanded reduction in thrust, was able to be turned on and off by manipulating cloud TWC. A flight test point where no ice crystal icing event occurred was also duplicated in PSL. Physics based computational tools were successfully used to predict tunnel settings to induce ice buildup along the low pressure compression system flow path for several test points at incrementally lower altitudes, demonstrating that development of ice crystal icing scaling laws is potentially feasible. Analysis of PSL test data showed that uncommanded reduction in thrust occurs during ice crystal cloud on operation prior to fan speed reduction. This supports previous findings that the reduction of thrust for this test article is due to ice buildup leading to a restricted airflow from either physical or aerodynamic blockage in the engine core flow path.

Turbofan Engine↗

NASA NTRS1994

Quantitative investigation of compressible mixing: Staged transverse injection into Mach 2 flow

Planar measurements of the injectant mole fraction distribution and the velocity field within a supersonic mixing flowfield have been made using laser-induced iodine fluorescence. The flowfield investigated in this work is staged transverse injection of air into a Mach 2 freestream. A complete three-dimensional survey of the injectant mole fraction distribution has been generated, and a single planar velocity measurement has been completed. The measurements reveal the dramatic effect of streamwise vortices on the mixing in the near field of the injectors, as well as the rapid mixing generated by staging two fuel injectors. Analysis of the downstream decay of the maximum injectant mole fraction in this and other supersonic mixing flowfields indicates that the relative rate of injectant mixing well downstream of the injectors is independent of injection geometry, freestream Mach number, and injectant molecular weight. Mixing within this region of the flowfield is dominated by small-scale turbulence within the injectant plume. The transition of the dominant mixing mechanism, from vortex-driven mixing in the near field to small-scale turbulent mixing in the far field, was found to occur in the region about 10 diameters downstream of the injectors.

Hollo, Steven D.↗

NASA NTRS1975

Design and the parametric testing of the space station prototype integrated vapor compression distillation water recovery module

Potable water for the Space Station Prototype life support system is generated by the vapor compression technique of vacuum distillation. A description of a complete three-man modular vapor compression water renovation loop that was built and tested is presented; included are all of the pumps, tankage, chemical post-treatment, instrumentation, and controls necessary to make the loop representative of an automatic, self-monitoring, null gravity system. The design rationale is given and the evolved configuration is described. Presented next are the results of an extensive parametric test during which distilled water was generated from urine and urinal flush water with concentration of solids in the evaporating liquid increasing progressively to 60 percent. Water quality, quantity and production rate are shown together with measured energy consumption rate in terms of watt-hours per kilogram of distilled water produced.

Reveley, W. F.↗

NASA NTRS1989

Stability of compressible boundary layers

The stability of compressible 2-D and 3-D boundary layers is reviewed. The stability of 2-D compressible flows differs from that of incompressible flows in two important features: There is more than one mode of instability contributing to the growth of disturbances in supersonic laminar boundary layers and the most unstable first mode wave is 3-D. Whereas viscosity has a destabilizing effect on incompressible flows, it is stabilizing for high supersonic Mach numbers. Whereas cooling stabilizes first mode waves, it destabilizes second mode waves. However, second order waves can be stabilized by suction and favorable pressure gradients. The influence of the nonparallelism on the spatial growth rate of disturbances is evaluated. The growth rate depends on the flow variable as well as the distance from the body. Floquet theory is used to investigate the subharmonic secondary instability.

Nayfeh, Ali H.↗

NASA NTRS1978

Hot forming of silicon sheet, silicon sheet growth development for the large area silicon sheet task of the low cost silicon solar array project

The hot workability of polycrystalline silicon was studied. Uniaxail stress-strain curves are given for strain rates in the range of .0001 to .1/sec and temperatures from 1100 to 1380 C. At the highest strain rates at 1380 C axial strains in excess of 20% were easily obtainable without cracking. After deformations of 36%, recrystallization was completed within 0.1 hr at 1380 C. When the recrystallization was complete, there was still a small volume fraction of unrecyrstallized material which appeared very stable and may degrade the electronic properties of the bulk materials. Texture measurements showed that the as-produced vapor deposited polycrystalline rods have a 110 fiber texture with the 110 direction parallel to the growth direction and no preferred orientation about this axis. Upon axial compression perpendicular to the growth direction, the former 110 fiber axis changed to 111 and the compression axis became 110 . Recrystallization changed the texture to 110 along the former fiber axis and to 100 along the compression axis.

Graham, C. D., Jr.↗

NASA NTRS1993

Calibrating rates of early Cambrian evolution

An explosive episode of biological diversification occurred near the beginning of the Cambrian period. Evolutionary rates in the Cambrian have been difficult to quantify accurately because of a lack of high-precision ages. Currently, uranium-lead zircon geochronology is the most powerful method for dating rocks of Cambrian age. Uranium-lead zircon data from lower Cambrian rocks located in northeast Siberia indicate that the Cambrian period began about 544 million years ago and that its oldest (Manykaian) stage lasted no less than 10 million years. Other data indicate that the Tommotian and Atdabanian stages together lasted only 5 to 10 million years. The resulting compression of Early Cambrian time accentuates the rapidity of both the faunal diversification and subsequent Cambrian turnover.

Bowring, Samuel A.↗

NASA NTRS1998

Life Testing of the Vapor Compression Distillation/Urine Processing Assembly (VCD/UPA) at the Marshall Space Flight Center (1993 to 1997)

Wastewater and urine generated on the International Space Station will be processed to recover pure water using vapor compression distillation (VCD). To verify the long-term reliability and performance of the VCD Urine Processor Assembly (UPA), life testing was performed at the Marshall Space Flight Center (MSFC) from January 1993 to April 1996. Two UPA'S, the VCD-5 and VCD-5A, were tested for 204 days and 665 days, respectively. The compressor gears and the distillation centrifuge drive belt were found to have operating lives of approximately 4,800 hours, equivalent to 3.9 years of operation on ISS for a crew of three at an average processing rate of 1.76 kg/h (3.97 lb/h). Precise alignment of the flex-splines of the fluids and purge pump motor drives is essential to avoid premature failure after about 400 hours of operation. Results indicate that, with some design and procedural modifications and suitable quality control, the required performance and operational life can be met with the VCD/UPA.

Wieland, P.↗

NASA NTRSDate not supplied

Ground Test Stand Development for One-step Electrochemical Production of High-Pressure Oxygen

NASA designed a test rig, High-Pressure Oxygen Generation Assembly (HPOGA) to test a novel method of electrolysis as an alternative technology to the state-of-the-art Oxygen Generation Assembly (OGA) currently on the International Space Station (ISS). This approach involves utilizing a specialized electrolysis cell stack designed to both generate and compress high-pressure oxygen up to 3600 PSIG. The design eliminates the need for an external compressor and hydrogen separator, streamlining the oxygen generation process. HPOGA tests the viability of an electrolysis cell stack for extended life usage. Within the system, there are several key subsystems: nitrogen, high/low pressure oxygen, hydrogen, water recirculation, and water injection. The water injection subsystem supplies deionized (DI) water to a centralized reservoir for consumption. Subsequently, a water recirculation loop transfers the DI water across the cathode side of the electrolysis cell stack with constant flow rate. The result is a supply of hydrogen in the water loop and oxygen accumulation on the anode side of the cell stack. Hydrogen is evaporated out as part of the hydrogen sub-system which also measures hydrogen/oxygen concentration for safety. The oxygen subsystem is responsible for managing high pressure oxygen, O2 exhaust, and conducting hydrogen/oxygen concentration measurements. The nitrogen subsystem serves dual functions, purging the hydrogen/oxygen subsystems, and regulating pressure in both high/low-pressure O2 sections via pneumatic back pressure regulators. Various sensors monitor pressure, temperature, humidity, gas concentration and flow rate in each subsystem. This paper presents the design and testing of a comprehensive test stand, which serves to operate and functionally verify the performance of the electrolysis cell while offering valuable lessons learned.

electrolysis↗

NASA NTRS2000

Slowly and Rapidly Propagating "Liquid Flames" in Gravitational Fields

We consider the combustion, in a gravitational field, of a heterogeneous powder mixture compressed into a solid sample, in which the high temperature ahead of the reaction zone destroys the solid, due, e.g. to melting of some of components of the mixture. Thus, a suspension is formed, consisting of a liquid bath containing solid or liquid particles. Processes such as heat and mass transfer as well as chemical reactions in the suspension determine the structure of the combustion wave and its propagation velocity. Under the influence of gravitational forces there is the possibility of relative motion of the liquid and solid. Previous theoretical analyses considered the rate of beat transfer between the solid and liquid phases to be sufficiently large that their two distinct temperatures rapidly equilibrated to a single temperature. In addition to this case, we also consider the case when the rate of heat transfer is not so large and the model involves the separate temperatures of the solid and liquid phases. We find that multiplicity of traveling wave structures is possible. In particular, in addition to a low velocity structure, which is essentially the same as that obtained from the one temperature description, we find a high velocity structure, which does not exist in the one temperature description, but rather depends on the fact that the solid and fluid temperatures differ from each other. Both structures can exist for the same parameter values in a given range. We describe the dependence of the combustion characteristics of the two structures on gravitational forces and other factors. In particular, we compare the characteristics in gravity and microgravity environments.

Shkadinsky, K. G.↗

NASA NTRS2008

Forebody and Inlet Design for the HIFiRE 2 Flight Test

A forebody and inlet have been designed for the HIFiRE 2 scramjet flight test. The test will explore the operating, performance, and stability characteristics of a simple hydrocarbon-fueled scramjet combustor as it transitions from dual-mode to scramjet-mode operation and during supersonic combustion at Mach 8+ flight conditions. Requirements for the compression system were derived from inlet starting and combustor inflow requirements as well as physical size constraints. The design process is described. A planar, fixed geometry, mixed compression concept was used to produce laterally uniform flow at the inlet entrance and a conservative amount of internal contraction with respect to inlet starting. A grid sensitivity study was performed so that important flow physics caused by three-dimensional shock boundary layer interactions could be captured with confidence. Results from low Mach number operability studies, nominal trajectory cases, and high dynamic pressure heat load cases are discussed. The forebody and inlet solutions provide information for on-going combustor calculations, mass capture across the trajectory for fuel system design, and surface heating rates for thermal/structural analysis. The design has a one freestream Mach number margin for inlet starting, exceeds the high Mach number combustor entrance pressure requirement, produces high quality flow at the inlet exit for all Mach numbers and vehicle attitudes in the design space, and fits inside the booster shroud.

Ferlemann, Paul G.↗

NASA NTRS1934

A Preliminary Motion-picture Study of Combustion in a Compression-ignition Engine

Motion pictures were taken at 1,850 frames per second of the spray penetration and combustion occurring in the N.A.C.A. combustion apparatus arranged to operate as a compression-ignition engine. Indicator cards were taken simultaneously with the motion pictures by means of the N.A.C.A. optical indicator. The motion pictures showed that when ignition occurred during injection it started in the spray envelope. If ignition occurred after injection cut-off, however, and after considerable mixing had taken place, it was impossible to predict where the ignition would start. The pictures also showed that ignition usually started at several points in the combustion chamber. With this apparatus, as the injection advance angle increased from 0 degrees to 40 degrees before top center, the rate of flame spread increased and the duration of the burning decreased.

Buckley, E C↗

NASA NTRS1989

Zonal multigrid solution of compressible flow problems on unstructured and adaptive meshes

The simultaneous use of adaptive meshing techniques with a multigrid strategy for solving the 2-D Euler equations in the context of unstructured meshes is studied. To obtain optimal efficiency, methods capable of computing locally improved solutions without recourse to global recalculations are pursued. A method for locally refining an existing unstructured mesh, without regenerating a new global mesh is employed, and the domain is automatically partitioned into refined and unrefined regions. Two multigrid strategies are developed. In the first, time-stepping is performed on a global fine mesh covering the entire domain, and convergence acceleration is achieved through the use of zonal coarse grid accelerator meshes, which lie under the adaptively refined regions of the global fine mesh. Both schemes are shown to produce similar convergence rates to each other, and also with respect to a previously developed global multigrid algorithm, which performs time-stepping throughout the entire domain, on each mesh level. However, the present schemes exhibit higher computational efficiency due to the smaller number of operations on each level.

Mavriplis, Dimitri J.↗

NASA NTRS1986

Application of CFD to aerothermal heating problems

Numerical solutions of the compressible Navier-Stokes equations by an Alternating Direction Implicit scheme, applied to two experimental investigations at NASA Langley Research Center are presented. The first is cooling by injection of a gas jet through the nose of an ogive-cone, and the second is the aerothermal environment in the gap formed by the wing and elevon section of a test model of the Space Shuttle. The simulations demonstrate that accurate pressure calculations are easily obtained on a coarse grid, witih convergence being obtained after the residual reduces by four orders of magnitude. However, accurate heating rates require a fine grid solution, with convergence requiring at least a reduction of six orders of magnitude in the residual. The effect of artificial dissipation on numerical results is also assessed.

Macaraeg, M. G.↗

NASA NTRS1987

Vapor Compression Distillation Subsystem (VCDS) component enhancement, testing and expert fault diagnostics development, volume 1

Vapor compression distillation technology for phase change recovery of potable water from wastewater has evolved as a technically mature approach for use aboard the Space Station. A program to parametrically test an advanced preprototype Vapor Compression Distillation Subsystem (VCDS) was completed during 1985 and 1986. In parallel with parametric testing, a hardware improvement program was initiated to test the feasibility of incorporating several key improvements into the advanced preprototype VCDS following initial parametric tests. Specific areas of improvement included long-life, self-lubricated bearings, a lightweight, highly-efficient compressor, and a long-life magnetic drive. With the exception of the self-lubricated bearings, these improvements are incorporated. The advanced preprototype VCDS was designed to reclaim 95 percent of the available wastewater at a nominal water recovery rate of 1.36 kg/h achieved at a solids concentration of 2.3 percent and 308 K condenser temperature. While this performance was maintained for the initial testing, a 300 percent improvement in water production rate with a corresponding lower specific energy was achieved following incorporation of the improvements. Testing involved the characterization of key VCDS performance factors as a function of recycle loop solids concentration, distillation unit temperature and fluids pump speed. The objective of this effort was to expand the VCDS data base to enable defining optimum performance characteristics for flight hardware development.

Kovach, L. S.↗

NASA NTRS1989

Numerical models of two complex hypersonic flowfields

Numerical solutions of the compressible Navier-Stokes equations assuming a perfect gas and laminar flow are applied to two hypersonic experiments conducted at NASA Langley Research Center. The first is cooling by injection of a gas jet through the nose of an ogive-cone, and the second is the aerothermal environment in the gap formed by the wing and elevon section of a test model of the Space Shuttle. The simulations demonstrate that the model predicts accurate pressures and shock stand-off for the gas jet and accurate pressures for the wing-elevon cove. Experimental heating rates for the gas jet indicate turbulent mixing to be occurring, an effect not modeled in the numerical solution.

Macaraeg, M. G.↗

NASA NTRS1989

A fully-coupled implicit method for thermo-chemical nonequilibrium air at sub-orbital flight speeds

A CFD technique is described in which the finite-rate chemistry in thermal and chemical nonequilibrium air is fully and implicitly coupled with the fluid motion. Developed for use in the suborbital hypersonic flight speed range, the method accounts for nonequilibrium vibrational and electronic excitation and dissociation, but not ionization. The steady-state solution to the resulting system of equations is obtained by using a lower-upper factorization and symmetric Gauss-Seidel sweeping technique through Newton iteration. Inversion of the left-hand-side matrices is replaced by scalar multiplications through the use of the diagonal dominance algorithm. The code, named CENS2H (Compressible-Euler-Navier-Stokes Two-Dimensional Hypersonic), is fully vectorized and requires about 8.8 x 10 to the -5th sec per node point per iteration using a Cray X-MP computer. Converged solutions are obtained after about 2400 iterations. Sample calculations are made for a circular cylinder and a 10 percent airfoil at 5 deg angle of attack. The calculated cylinder flow field agrees with that obtained experimentally. The code predicts a 10 percent change in lift, drag, and pitching moment for the airfoil due to the thermochemical phenomena.

Park, Chul↗

NASA NTRS1991

Numerical simulations of turbulent thermal convection with differential rotation

The solar nebula, from which the planets in our solar system formed, featured a disk of gas and dust grains in rapid, differential rotation, and at some stage was likely to have been unstable to thermal convection. This situation is suspected by many to lead to significant turbulent Reynolds stress production and angular momentum transport in such systems, and estimates of transport rates have been attempted from unsubstantiated phenomenological models. In order to determine the circumstances and physical conditions under which our own planetary system formed and to explain recent observations of young stellar systems, it is necessary to develop realistic models of heat and angular momentum transport for such flows. Developing an understanding of complicated flows featuring thermal convection, rotation, and shear is also of wide interest in stellar astrophysics and in planetary and terrestrial atmospheric studies. The ultimate objective is to develop workable models based on the numerical simulations for constructing global solar nebula models; viz., relatively simple prescriptions for heat and angular momentum fluxes from given system parameters (e.g., ratios of rotation, shear, and convective lapse rates) are characterized, quantified, and developed. Toward this end, our program has been to attempt to understand the behavior of the direct numerical simulations of Boussinesq convection, which, despite the complexity of the results, is still an overly simplified approximation to the real system and should be more amenable to analysis. These results are also intended to be tested against turbulence models, especially those designed for atmospheric boundary layers, and may provide a basis for subgrid-scale models. In order to make the numerical simulations more realistic with regard to the solar nebula problem, a fully compressible code that will allow incorporation of large density stratifications and realistic thermodynamic and radiative properties is developed. In order to explore the properties of these flows at the very high values of Re found in natural systems and the very low values of Pr found in most astrophysical contexts, we will need to employ large-eddy simulations for which we want to determine the most appropriate subgrid-scale model to incorporate.

Cabot, William H.↗