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NASA NTRS1991

User's manual for rocket combustor interactive design (ROCCID) and analysis computer program. Volume 2: Appendixes A-K

The appendices A-K to the user's manual for the rocket combustor interactive design (ROCCID) computer program are presented. This includes installation instructions, flow charts, subroutine model documentation, and sample output files. The ROCCID program, written in Fortran 77, provides a standardized methodology using state of the art codes and procedures for the analysis of a liquid rocket engine combustor's steady state combustion performance and combustion stability. The ROCCID is currently capable of analyzing mixed element injector patterns containing impinging like doublet or unlike triplet, showerhead, shear coaxial and swirl coaxial elements as long as only one element type exists in each injector core, baffle, or barrier zone. Real propellant properties of oxygen, hydrogen, methane, propane, and RP-1 are included in ROCCID. The properties of other propellants can be easily added. The analysis models in ROCCID can account for the influences of acoustic cavities, helmholtz resonators, and radial thrust chamber baffles on combustion stability. ROCCID also contains the logic to interactively create a combustor design which meets input performance and stability goals. A preliminary design results from the application of historical correlations to the input design requirements. The steady state performance and combustion stability of this design is evaluated using the analysis models, and ROCCID guides the user as to the design changes required to satisfy the user's performance and stability goals, including the design of stability aids. Output from ROCCID includes a formatted input file for the standardized JANNAF engine performance prediction procedure.

Muss, J. A.↗

NASA NTRS1985

The structure of dilute combusting sprays

An experimental and theoretical study of drop processes in a turbulent flame is described. The experiments involved a monodisperse (105 and 180 micro m initial diameter) stream of methanol drops injected at the base of a turbulent methane-fueled diffusion flame burning in still air. The following measurements were made: mean and fluctuating phase velocities, mean drop number flux, drop-size distributions and mean gas-phase temperatures. Measurements were compared with predictions of two separated flow models: (1) deterministic separated flow, where drop-turbulence interactions are ignored; and (2) stochastic separated flow, where drop-turbulence interactions are considered using random-walk computations. The stochastic separated flow analysis yielded best agreement with measurements, since it provides for turbulent dispersion of drops which was important for present test conditions (and probably for most combusting sprays as well). Distinguishing the presence or absence of envelope flames around the drops, however, was relatively unimportant for present test conditions, since the drops spent most of their lifetime in fuel-rich regions of the flow where this distinction is irrelevant.

Shuen, J. S.↗

NASA NTRS2012

Quantitative Thermochemical Measurements in High-Pressure Gaseous Combustion

We present our strategic experiment and thermochemical analyses on combustion flow using a subframe burst gating (SBG) Raman spectroscopy. This unconventional laser diagnostic technique has promising ability to enhance accuracy of the quantitative scalar measurements in a point-wise single-shot fashion. In the presentation, we briefly describe an experimental methodology that generates transferable calibration standard for the routine implementation of the diagnostics in hydrocarbon flames. The diagnostic technology was applied to simultaneous measurements of temperature and chemical species in a swirl-stabilized turbulent flame with gaseous methane fuel at elevated pressure (17 atm). Statistical analyses of the space-/time-resolved thermochemical data provide insights into the nature of the mixing process and it impact on the subsequent combustion process in the model combustor.

Kojima, Jun J.↗

NASA NTRS1991

Lightweight ceramic components for propulsion applications

It is demonstrated that two ceramic engine components of reduced weight can be efficiently produced and employed at higher combustion gas temperatures. The engine components, containing internal cooling and hydraulic passages, are fabricated in a process involving platelet technology, tape casting, and multilayer ceramic packaging techniques. Traditional metal platelet design techniques are used to fabricate components from ceramic tape which are then laminated and processed to densities of close to 100 percent. A methane cooled regenerator for an air turbo ramjet engine and a rocket engine bipropellant injector are fabricated from silicon nitride. The two components are tested under conditions similar to the pressurization, thrusts, and temperatures encountered in a combustion gas environment. The survivability and leak-free nature of the components demonstrate that more complex ceramic engine components can be fabricated using these techniques.

Franklin, J. E.↗

NASA NTRS1997

Potential New Sensor for Use With Conventional Gas Carburizing

Diagnostics developed for in-situ monitoring of rocket combustion environments have been adapted for use in heat treating furnaces. Simultaneous, in-situ monitoring of the carbon monoxide, carbon dioxide, methane, water, nitrogen and hydrogen concentrations in the endothermic gas of a heat treating furnace has been demonstrated under a Space Act Agreement between NASA Lewis, the Heat Treating Network, and Akron Steel Treating Company. Equipment installed at the Akron Steel Treating Company showed the feasibility of the method. Clear and well-defined spectra of carbon monoxide, nitrogen and hydrogen were obtained by means of an optical probe mounted on the endothermic gas line of a gas generator inside the plant, with the data reduction hardware located in the basement laboratory. Signals to and from the probe were transmitted via optical fibers.

deGroot, W. A.↗

NASA NTRS1983

A comprehensive model to determine the effects of temperature and species fluctuations on reaction rates in turbulent reacting flows

Reaction rates in turbulent, reacting flows are reviewed. Assumed probability density functions (pdf) modeling of reaction rates is being investigated in relation to a three variable pdf employing a 'most likely pdf' model. Chemical kinetic mechanisms treating hydrogen air combustion is studied. Perfectly stirred reactor modeling of flame stabilizing recirculation regions was used to investigate the stable flame regions for silane, hydrogen, methane, and propane, and for certain mixtures thereof. It is concluded that in general, silane can be counted upon to stabilize flames only when the overall fuel air ratio is close to or greater than unity. For lean flames, silane may tend to destabilize the flame. Other factors favoring stable flames are high initial reactant temperatures and system pressure.

Goldstein, D.↗

NASA NTRS2016

Additively Manufactured Combustion Devices Components for LOX/Methane Applications

Marshall Space Flight Center (MSFC) has designed, fabricated, and hot-fire tested a variety of successful injectors, chambers, and igniters for potential liquid oxygen (LOX) and methane (CH4) systems since 2005. The most recent efforts have focused on components with additive manufacturing (AM) to include unique design features, minimize joints, and reduce final machining efforts. Inconel and copper alloys have been used with AM processes to produce a swirl coaxial injector and multiple methane cooled thrust chambers. The initial chambers included unique thermocouple ports for measuring local coolant channel temperatures along the length of the chamber. Results from hot-fire testing were used to anchor thermal models and generate a regeneratively cooled thruster for a 4,000 lbf LOX/CH4 engine. The completed thruster will be hot-fire tested in the summer of 2016 at MSFC. The thruster design can also be easily scaled and used on a 25,000 lbf engine. To further support the larger engine design, an AM gas generator injector has been designed. Hot-fire testing on this injector is planned for the summer of 2016 at MSFC.

Greene, Sandra Elam↗

NASA NTRS1991

Investigation of hypersonic ramjet propulsion cycles using a ram accelerator test facility

Experimental research on hypersonic propulsion using a ram accelerator test facility is presented. The gasdynamics of the ram accelerator has been studied experimentally in a 38-mm bore facility over the Mach number range of 2.5 to 8.5, using methane- and ethylene-based propellant mixtures. Three different propulsive modes, centered on the Chapman-Jouguet (C-J) detonation speed of the combustible gas, have been experimentally observed. Projectiles have been accelerated smoothly from velocities below to above the C-J speed within a single propellant mixture.

Bruckner, A. P.↗

NASA NTRS2008

LOX/Methane Main Engine Igniter Tests and Modeling

The LOX/methane propellant combination is being considered for the Lunar Surface Access Module ascent main engine propulsion system. The proposed switch from the hypergolic propellants used in the Apollo lunar ascent engine to LOX/methane propellants requires the development of igniters capable of highly reliable performance in a lunar surface environment. An ignition test program was conducted that used an in-house designed LOX/methane spark torch igniter. The testing occurred in Cell 21 of the Research Combustion Laboratory to utilize its altitude capability to simulate a space vacuum environment. Approximately 750 ignition test were performed to evaluate the effects of methane purity, igniter body temperature, spark energy level and frequency, mixture ratio, flowrate, and igniter geometry on the ability to obtain successful ignitions. Ignitions were obtained down to an igniter body temperature of approximately 260 R with a 10 torr back-pressure. The data obtained is also being used to anchor a CFD based igniter model.

Breisacher, Kevin J.↗

NASA NTRS2001

NASA National Combustion Code Simulations

A systematic effort is in progress to further validate the National Combustion Code (NCC) that has been developed at NASA Glenn Research Center (GRC) for comprehensive modeling and simulation of aerospace combustion systems. The validation efforts include numerical simulation of the gas-phase combustor experiments conducted at the Center for Turbulence Research (CTR), Stanford University, followed by comparison and evaluation of the computed results with the experimental data. Presently, at GRC, a numerical model of the experimental gaseous combustor is built to simulate the experimental model. The constructed numerical geometry includes the flow development sections for air annulus and fuel pipe, 24 channel air and fuel swirlers, hub, combustor, and tail pipe. Furthermore, a three-dimensional multi-block, multi-grid grid (1.6 million grid points, 3-levels of multi-grid) is generated. Computational simulation of the gaseous combustor flow field operating on methane fuel has started. The computational domain includes the whole flow regime starting from the fuel pipe and the air annulus, through the 12 air and 12 fuel channels, in the combustion region and through the tail pipe.

Iannetti, Anthony↗

NASA NTRS1958

Theoretical Rocket Performance of Liquid Methane with Several Fluorine-Oxygen Mixtures Assuming Frozen Composition

Theoretical rocket performance for frozen composition during expansion was calculated for liquid methane with several fluorine-oxygen mixtures for a range of pressure ratios and oxidant-fuel ratios. The parameters included are specific impulse, combustion-chamber temperature, nozzle-exit temperature molecular weight, characteristic velocity, coefficient of thrust, ratio of nozzle-exit area to throat area, specific heat at constant pressure, isentropic exponent, viscosity, and thermal conductivity. The maximum calculated value of specific impulse for a chamber pressure of 600 pounds per square inch absolute (40.827atm) and an exit pressure of 1 atmosphere is 315.3 for 79.67 percent fluorine in the oxidant.

Gordon, Sanford↗

NASA NTRS2015

Summary of LOX/CH4 Thruster Technology Development at NASA/MSFC

In recent years, a variety of injectors for liquid oxygen (LOX) and methane (CH4) propellant systems have been designed, fabricated, and demonstrated with hot-fire testing at Marshall Space Flight Center (MSFC). Successful designs for liquid methane (LCH4) and gaseous methane (GCH4) have been developed. A variety of chambers, including a transpiration cooled design, along with uncooled ablatives and refractory metals, have also been hot-fire tested by MSFC for use with LOX/LCH4 injectors. Hot-fire testing has also demonstrated multiple ignition source options. Heat flux data for selected injectors has been gathered by testing with a calorimeter chamber. High performance and stable combustion have been demonstrated, along with designs for thrust levels ranging from 500 to 7,000 lbf. The newest LOX/CH4 injector and chamber developed by MSFC have been fabricated with additive manufacturing techniques and include unique design features to investigate regenerative cooling with methane. This low cost and versatile hardware offers a design for 4,000 lbf thrust and will be hot-fire tested at MSFC in 2015. Its design and operation can easily be scaled for use in systems with thrust levels up to 25,000 lbf.

Greene, Sandra Elam↗

NASA NTRS1990

Corrosion Prevention in Copper Combustion Chamber Liners of Liquid Oxygen/Methane Booster Engines

Prior research conducted by United Technologies Research Center and Rockwell International Rocketdyne Division encountered severe copper corrosion while flowing hydrocarbon fuels through copper cooling tubes. These experimental results have very important implications for the development of low-cost, regeneratively cooled, oxygen/hydrocarbon bipropellant booster engines. Aerojet TechSystems undertook a program sponsored by NASA/Lewis Research Center in 1986 with two objectives: (1) to define the corrosive interaction process that occurs between hydrocarbon fuels and copper combustion chamber liner materials, using both static and dynamic test methods, and (2) to identify and demonstrate protective measures against this corrosive process. The results of the first program task demonstrated that the most damaging corrosive process was caused by trace amounts of sulfur-containing impurities in the hydrocarbon fuel which react with the copper chamber liner material to form cuprous sulfide (Cu2S), as reported in Paper No. AlAA 88-3215. Experiments were conducted which demonstrated this corrosive process with Mil-Spec RP-1, propane, and methane fuels in contact with OFHC, NASA-Z, and ZrCu coppers. The preliminary results of the second program task demonstrated that electrodeposited gold and platinum coatings held promise of preventing corrosion of copper chamber liners by methane contaminated with sulfur-containing impurities, as reported in Paper No. AIAA 89-2738. Experiments were conducted which demonstrated greatly reduced corrosion of copper by hydrogen sulfide (H2S) and methyl mercaptan (CH3SH) as measured impurities in methane. This paper presents the concluding, confirmatory results from the second program task. The efficacy of a protective gold coating on NASA-Z copper cooling channel walls was conclusively demonstrated. Tests were conducted in the Aerojet Carbothermal Test Facility which provide realistic simulations of booster engine cooling channel conditions such as temperature, pressure, flow velocity, and heat flux. Dynamic test series were performed with methane containing 5 and 10 ppm (by volume) hydrogen sulfide. Gold-plated and unplated copper alloy specimens were evaluated. The tests demonstrated that gold coatings were effective in preventing corrosion of the copper. Posttest metallographic examinations of the unplated specimens showed severe corrosion as a result of reaction with the sulfur containing contaminant in the fuel. In contrast, posttest metallographic examination of the gold-coated specimens showed no corrosion under similar operating conditions. The findings from metallurgical and chemical analyses of the copper specimens, chemical analysis of the methane, and description of all test conditions are provided. Conclusions are reached as to the efficacy of the plating methods and the effectiveness of the metal coatings in the prevention of corrosion in hydrocarbon-fueled booster engine combustion chamber liners.

S D Rosenberg↗

NASA NTRS1987

Design concept for LOX/hydrocarbon tripropellant booster engine

The design concept for a LOX/hydrocarbon tripropellant booster engines is discussed. The engine design is for the gas generator cycle with liquid methane, liquid oxygen, and liquid hydrogen as propellants, the latter greatly reducing risks associated with the high-pressure reusable hydrocarbon booster engines. The design features high combustion stability and high efficiency. The excellent cooling capability of liquid hydrogen was established in several operational engine designs. Multiple design diagrams are included.

Visek, W. A., Jr.↗

NASA NTRS1992

Extraterrestrial surface propulsion systems

Lunar traction systems, Mars oxygen production, and Mars methane engine operation were the three topics studied during 1992. An elastic loop track system for lunar construction operations was redesigned and is being tested. A great deal of work on simulating the lunar environment to facilitate traction testing has been reported. Operation of an oxygen processor under vacuum conditions has been the focus of another design team. They have redesigned the processor facility. This included improved seals and heat shields. Assuming methane and oxygen can be produced from surface resources on Mars, a third design team has addressed the problem of using Mars atmospheric carbon dioxide to control combustion temperatures in an internal combustion engine. That team has identified appropriate tests and instrumentation. They have reported on the test rig that they designed and the computer-based system for acquiring data.

Ash, Robert L.↗

NASA NTRS1993

Studies of droplet burning and extinction

A project on droplet combustion, pursued jointly with F.L. Dryer of Princeton University, has now been in progress for many years. The project involves experiments on the burning of single droplets in various atmospheres, mainly at normal atmosperic pressure and below, performed in drop towers and designed to be performed aboard space-based platforms such as the Space Shuttle or the Space Station. It also involves numerical computations on droplet burning, performed mainly at Princeton, and asymptotic analyses of droplet burning, performed mainly at UCSD. The focus of the studies rests primarily on time-dependent droplet-burning characteristics and on extinction phenomena. The presentation to be given here concerns the recent research on application of asymptotic methods to investigation of the flame structure and extinction of hydrocarbon droplets. These theoretical studies are investigating the extent to which combustion of higher hydrocarbons - heptane, in particular - can be described by four-step reduced chemistry of the kind that has achieved a good degree of success for methane flames. The studies have progressed to a point at which a number of definite conclusions can now be stated. These conclusions and the reasoning that led to them are outlined here.

Williams, Forman A.↗

NASA NTRS2001

Microgravity Diode Laser Spectroscopy Measurements in a Reacting Vortex Ring

The technique of Diode Laser Spectroscopy (DLS) with wavelength modulation is utilized to measure the concentration of methane in reacting vortex rings under microgravity conditions. From the measured concentration of methane, other major species such as water, carbon dioxide, nitrogen, and oxygen can be easily computed under the assumption of equilibrium chemistry with an iterative method called ITAC (Iterative Temperature with Assumed Chemistry). The conserved scalar approach in modelling the coupling between fluid dynamics and combustion is utilized to represent the unknown variables in terms of the mixture fraction and scalar dissipation rate in conjunction with ITAC. Post-processing of the DLS and the method used to compute the species concentration are discussed. From the flame luminosity results, ring circulation appears to increase the fuel consumption rate inside the reacting vortex ring and the flame height for cases with similar fuel volumes but different ring circulations. The concentrations of methane, water, and carbon dioxide agree well with available results from numerical simulations.

Chen, Shin-Juh↗

NASA NTRS1995

Effects of confinement on partially premixed flames

Partially premixed combustion is an intermediate regime between the limiting cases of premixed and nonpremixed combustion. Although combustion problems are generally approached from one of these two limiting cases, there are many practical situations where flames cannot be considered as purely premixed or nonpremixed, and thus the partially premixed approach must be used. In partially premixed combustion, mechanisms from the premixed and nonpremixed regimes can coexist, and as a result some interesting new phenomena can arise. One such phenomenon is the flame stabilization in laminar mixing layers by triple flames. One of the first observations of triple flames was made by Phillips (1965), who investigated a triple flame propagating in a methane mixing layer. Kioni et al. (1993) also examined triple flames both experimentally and numerically. There have also been numerous analytical studies on the shape and propagation of triple flames under various assumptions by Dold (1989), Dold et al. (1991), and Hartley and Dold (1991). In terms of modeling, Muller et al. (1994) have combined the flamelet formulations for premixed and nonpremixed combustion in order to treat lifted diffusion flames. One common feature in the analytical and numerical studies mentioned above is the assumption of zero heat release, which is necessary to make the problem tractable. The effect of heat release on triple flames was investigated by Ruetsch et al. (1995), where for the unconfined case, flame speeds larger than their premixed counterparts were found. One of the most important practical situations in which these conditions arise is in lifted turbulent jet diffusion flames. At a critical velocity the burning zone of a fuel jet lifts off from the nozzle, moves to increasing distances as the jet velocity increases, and finally blows off. The mechanisms that control these phenomena, i.e. that determine the stability of these flames, are still not understood. In addition to regions where diffusion flame stabilization takes place, partially premixed conditions also exist during the ignition process in nonpremixed systems. Numerical simulations by Reveillon et al. (1994) of the ignition process in a weakly stirred mixture of fuel and oxidizer show that triple flames propagate along lines of stoichiometric mixture fraction throughout the fluid. In addition, Peters (1994) notes that NO(x) emissions are likely to be large in such transient cases, and therefore an understanding of triple flames can provide information concerning pollutant formation. This study extends the work previously done and examines the effects of lateral confinement on partially premixed flames. Once again, we study both the flame structure and propagation.

Ruetsch, G. R.↗