Development of electroforming techniques for the fabrication of rocket engine injectors Final report, phase 2
Electroforming techniques for fabrication of rocket engine injector using hypergolic fuel
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Electroforming techniques for fabrication of rocket engine injector using hypergolic fuel
Future aircraft turbine engines, both commercial and military, must be able to accommodate expected increased levels of steady-state and dynamic engine-face distortion. The current approach of incorporating sufficient design stall margin to tolerate these increased levels of distortion would significantly reduce performance. The objective of the High Stability Engine Control (HISTEC) program is to design, develop, and flight-demonstrate an advanced, integrated engine control system that uses measurement-based estimates of distortion to enhance engine stability. The resulting distortion tolerant control reduces the required design stall margin, with a corresponding increase in performance and decrease in fuel burn. The HISTEC concept has been developed and was successfully flight demonstrated on the F-15 ACTIVE aircraft during the summer of 1997. The flight demonstration was planned and carried out in two phases, the first to show distortion estimation, and the second to show distortion accommodation. Post-flight analysis shows that the HISTEC technologies are able to successfully estimate and accommodate distortion, transiently setting the stall margin requirement on-line and in real-time. This allows the design stall margin requirement to be reduced, which in turn can be traded for significantly increased performance and/or decreased weight. Flight demonstration of the HISTEC technologies has significantly reduced the risk of transitioning the technology to tactical and commercial engines.
A conceptual design and analysis on a single engine VSTOL fighter/attack aircraft is completed. The aircraft combines a NASA/deHavilland ejector with vectored thrust and is capable of accomplishing the mission and point performance of type Specification 169, and a flight demonstrator could be built with an existing F101/DFE engine. The aerodynamic, aero/propulsive, and propulsive uncertainties are identified, and a wind tunnel program is proposed to address those uncertainties associated with wing borne flight.
The IPD rocket engine is the product of a joint Air Force/NASA program to demonstrate the concept of a full-flow staged combustion power cycle. In this type of rocket engine cycle, both the entire fuel flow and the entire oxidizer flow are combusted in one of two pre-bumers and used to drive two turbopumps, thus utilizing the flow work of the total propellant flow. The basis of the IPD engine program relies on integrating newly developed and pre-existing hardware to demonstrate the component and material technologies to make this concept feasible, while simultaneously saving development time and costs. To provide insight to the project team and contractors during engine development and test phases, the engine system was modeled at MSFC using the Rocket Engine Transient Simulation (ROCETS) software to analyze system performance and determine component integration issues. The ROCETS software is used extensively a MSFC to perform steady-state power-balances and transient simulations of thermodynamic power and general fluid systems. The software is favored for its capability to solve large systems of non-linear equations, its librarie of fluid properties and flow devices, its flexibility to modify existing code to improve the physics-derived approximations of real fluid thermodynamic behavior, and the ability to add unique system constraints. The purpose of this paper is to present the methodology used to model the IPD engine system, detail the pitfalls encountered with the software, and explain the approximations made to more accurately represent engine component and fluid behavior. Engine system performance output from the model will be presented and explained in comparison with real fluid and component behavior.
This paper describes the results of acceptance testing of the Vapor Phase Catalytic Ammonia Removal (VPCAR) technology. The VPCAR technology is currently being developed by NASA as a Mars transit vehicle water recycling system. NASA has recently completed a grant to develop a next generation VPCAR system. This grant was peer reviewed and funded through the Advanced Life Support (ALS) National Research Announcement (NRA). The grant funded a contract with Water Reuse Technology Inc. to construct an engineering development unit. This contract concluded with the shipment of the final deliverable to NASA on 8/31/03. The objective of the acceptance testing was to characterize the performance of this new system. This paper presents the results of mass power, and volume measurements for the delivered system. In addition, product water purity analysis for a Mars transit mission and a planetary base wastewater ersatz are provided. Acoustic noise levels, interface specifications and system reliability results are also discussed. An assessment of the readiness of the technology for human testing and recommendations for future improvements are provided.
This paper describes the results of performance testing of the Vapor Phase Catalytic Ammonia Removal (VPCAR) technology. The VPCAR technology is currently being developed by NASA as a Mars transit vehicle water recycling system. NASA has recently completed-a grant-to develop a next generation VPCAR system. This grant concluded with the shipment of the final deliverable to NASA on 8/31/03. This paper presents the results of mass, power, volume, and acoustic measurements for the delivered system. Product water purity analysis for a Mars transit mission and a simulated planetary base wastewater ersatz are also provided.
An actuator includes a restraint link adapted to be connected with a pivotal carrier arm for a force transfer gear interposed between the crankshaft for an expander portion of a Stirling engine and a crankshaft for the displacer portion of the engine. The restraint link is releasably trapped hydraulic fluid for selectively establishing a phase angle relationship between the crankshaft. A second embodiment incorporates a hydraulic coupler for use in varying the phase angle of gear-coupled crank fpr a Stirling engine whereby phase angle changes are obtainable.
Engineering model of microwave phase shift controlled scanning phased antenna array for radar system
This paper describes an system of systems or metasystems approach and models developed to help prepare engineering organizations for distributed engineering environments. These changes in engineering enterprises include competition in increasingly global environments; new partnering opportunities caused by advances in information and communication technologies, and virtual collaboration issues associated with dispersed teams. To help address challenges and needs in this environment, a framework is proposed that can be customized and adapted for NASA to assist in improved engineering activities conducted in distributed, enhanced engineering environments. The approach is designed to prepare engineers for such distributed collaborative environments by learning and applying e-engineering methods and tools to a real-world engineering development scenario. The approach consists of two phases: an e-engineering basics phase and e-engineering application phase. The e-engineering basics phase addresses skills required for e-engineering. The e-engineering application phase applies these skills in a distributed collaborative environment to system development projects.
The development of optical techniques capable of measuring in-stream flow properties of air breathing hypersonic engines is a goal of the Aerospace Propulsion Division at AFRL. Of particular interest are techniques such as tunable diode laser absorption spectroscopy that can be implemented in both ground and flight test efforts. We recently executed a measurement campaign at the exit of the combustor of the HIFiRE 2 ground test engine during Phase II operation of the engine. Data was collected in anticipation of similar data sets to be collected during the flight experiment. The ground test optical data provides a means to evaluate signal processing algorithms particularly those associated with limited line of sight tomography. Equally important, this in-stream data was collected to compliment data acquired with surface-mounted instrumentation and the accompanying flowpath modeling efforts-both CFD and lower order modeling. Here we discuss the specifics of hardware and data collection along with a coarse-grained look at the acquired data and our approach to processing and analyzing it.
Hydrogen oxygen rocket engine two phase liquid hydrogen pump capability and hydrodynamic design, analyzing constant-quality flow, acoustic effects, compressible flow and cavitation
This report describes a pressure-measuring device especially adapted for use in mapping indicator diagrams of high-speed internal combustion engines. The cards are obtained by a point-to-point method giving the average of a large number of engine cycles. The principle involved is the balancing of the engine cylinder pressure against a measured pressure on the opposite side of the metal a diaphragm of negligible stiffness. In its application as an engine indicator the phase of the engine cycle to which a pressure measurement corresponds is selected by a timing device. The report discusses briefly the errors which must be avoided in the development of an indicator for light high-speed engines, where vibration is serious, and outlines the principles underlying the design of this instrument in order to be free of such errors. A detailed description of the instrument and accessories follows together with operating directions.
The use of liquid hydrogen to cool the rolling element radial bearings in the nuclear engine for rocket vehicles is discussed. The fifteen hour service life goal was obtained during the tests. The increase in bearing life was also considered to be produced by: (1) improvements in bearing material, (2) bearing retainer configuration and manufacturing changes, and (3) better control of operating parameters.
The effect of changes in the input parameters (air leakage flow rate and temperature and lubricating oil inlet flow rate and temperature) over a specified range on the flammability conditions within an aircraft engine bearing sump was investigated. An analytical study was performed to determine the effect of various parameters on the generation rate of oil vapor from oil droplets in a hot air stream flowing in a cylindrical tube. The ignition of the vapor-air mixture by an ignition source was considered. The experimental investigation demonstrated that fires would be ignited by a spark ignitor over the full range of air and oil flow rates and air temperatures evaluated. However, no fires could be ignited when the oil inlet temperature was maintained below 41.7 K (290 F). The severity of the fires ignited were found to be directly proportional to the hot air flow rate. Reasonably good correlation was found between the mixture temperature in the sump at the ignitor location and the flammability limits as defined by flammability theory; thus a fairly reliable experimental method of determining flammable conditions within a sump was demonstrated. The computerized mathematical model shows that oil droplet size and air temperature have the greatest influence on the generation rate of oil vapor.
The Landsat-D (now Landsat-4) program was initiated by NASA in the mid-1970's. The spacecraft was launched on July 16, 1982. Instruments on the satellite include the fourth Multispectral Scanner (MSS) and the new higher-resolution Thematic Mapper (TM). In order to achieve the planned engineering and scientific objectives, attention has to be given to the validation of spacecraft and instrument performance, the adjustment of ground processing procedures, and the definition of the measures of the TU utility. To satisfy these requirements, a Landsat Assessment System (LAS) was conceived, and the Applications Developmental Data System (ADDS) was instituted. The set of component systems collectively became known as the 'Scrounge' system. The present investigation is concerned with the Scrounge system and the results of radiometric and geometric data evaluations. Attention is given to the TM geometric correction, TM data resampling, a radiometric correction functional description, and the results of the TM geometric and radiometric correction.
The Space Shuttle Main Engine is a reusable, high-performance rocket engine being developed by the Rocketdyne Div. of Rockwell International to satisfy the operational requirements of the Space Shuttle Orbiter Vehicle. The design incorporates a hydraulically actuated, closed-loop servosystem controlled and monitored by a programmable electronic digital controller. The controller accepts vehicle commands for the various engine operational phases, positions the appropriate valves, monitors the engine for the required performance precisions and conditions, and provides redundancy management.
LibertyWorks®, a subsidiary of Rolls-Royce Corporation, first studied CMC (ceramic matrix composite) exhaust mixers for potential weight benefits in 2008. Oxide CMC potentially offered weight reduction, higher temperature capability, and the ability to fabricate complex-shapes for increased mixing and noise suppression. In 2010, NASA was pursuing the reduction of NOx emissions, fuel burn, and noise from turbine engines in Phase I of the Environmentally Responsible Aviation (ERA) Project (within the Integrated Systems Research Program). ERA subtasks, including those focused on CMC components, were being formulated with the goal of maturing technology from Proof of Concept Validation (Technology Readiness Level 3 (TRL 3)) to System/Subsystem or Prototype Demonstration in a Relevant Environment (TRL 6). LibertyWorks®, a subsidiary of Rolls-Royce Corporation, first studied CMC (ceramic matrix composite) exhaust mixers for potential weight benefits in 2008. Oxide CMC potentially offered weight reduction, higher temperature capability, and the ability to fabricate complex-shapes for increased mixing and noise suppression. In 2010, NASA was pursuing the reduction of NOx emissions, fuel burn, and noise from turbine engines in Phase I of the Environmentally Responsible Aviation (ERA) Project (within the Integrated Systems Research Program). ERA subtasks, including those focused on CMC components, were being formulated with the goal of maturing technology from Proof of Concept Validation (Technology Readiness Level 3 (TRL 3)) to System/Subsystem or Prototype Demonstration in a Relevant Environment (TRL 6). Oxide CMC component at both room and elevated temperatures. A TRL≈5 (Component Validation in a Relevant Environment) was attained and the CMC mixer was cleared for ground testing on a Rolls-Royce AE3007 engine for performance evaluation to achieve TRL 6.
Engineering feasibility study on structural dynamics, antenna electrical properties, and systems of kilometer wave orbiting telescope