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NASA NTRS1998

Current and Future Critical Issues in Rocket Propulsion Systems

The objective of this research was to tackle several problems that are currently of great importance to NASA. In a liquid rocket engine several complex processes take place that are not thoroughly understood. Droplet evaporation, turbulence, finite rate chemistry, instability, and injection/atomization phenomena are some of the critical issues being encountered in a liquid rocket engine environment. Pulse Detonation Engines (PDE) performance, combustion chamber instability analysis, 60K motor flowfield pattern from hydrocarbon fuel combustion, and 3D flowfield analysis for the Combined Cycle engine were of special interest to NASA. During the summer of 1997, we made an attempt to generate computational results for all of the above problems and shed some light on understanding some of the complex physical phenomena. For this purpose, the Liquid Thrust Chamber Performance (LTCP) code, mainly designed for liquid rocket engine applications, was utilized. The following test cases were considered: (1) Characterization of a detonation wave in a Pulse Detonation Tube; (2) 60K Motor wall temperature studies; (3) Propagation of a pressure pulse in a combustion chamber (under single and two-phase flow conditions); (4) Transonic region flowfield analysis affected by viscous effects; (5) Exploring the viscous differences between a smooth and a corrugated wall; and (6) 3D thrust chamber flowfield analysis of the Combined Cycle engine. It was shown that the LTCP-2D and LTCP-3D codes are capable of solving complex and stiff conservation equations for gaseous and droplet phases in a very robust and efficient manner. These codes can be run on a workstation and personal computers (PC's).

Navaz, Homayun K.↗

NASA NTRS1999

A Neural Network Aero Design System for Advanced Turbo-Engines

An inverse design method calculates the blade shape that produces a prescribed input pressure distribution. By controlling this input pressure distribution the aerodynamic design objectives can easily be met. Because of the intrinsic relationship between pressure distribution and airfoil physical properties, a Neural Network can be trained to choose the optimal pressure distribution that would meet a set of physical requirements. Neural network systems have been attempted in the context of direct design methods. From properties ascribed to a set of blades the neural network is trained to infer the properties of an 'interpolated' blade shape. The problem is that, especially in transonic regimes where we deal with intrinsically non linear and ill posed problems, small perturbations of the blade shape can produce very large variations of the flow parameters. It is very unlikely that, under these circumstances, a neural network will be able to find the proper solution. The unique situation in the present method is that the neural network can be trained to extract the required input pressure distribution from a database of pressure distributions while the inverse method will still compute the exact blade shape that corresponds to this 'interpolated' input pressure distribution. In other words, the interpolation process is transferred to a smoother problem, namely, finding what pressure distribution would produce the required flow conditions and, once this is done, the inverse method will compute the exact solution for this problem. The use of neural network is, in this context, highly related to the use of proper optimization techniques. The optimization is used essentially as an automation procedure to force the input pressure distributions to achieve the required aero and structural design parameters. A multilayered feed forward network with back-propagation is used to train the system for pattern association and classification.

Sanz, Jose M.↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design Using Classical and Optimal Techniques with Wind-Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using (1) classical, (2) linear quadratic Gaussian (LQG), and (3) minimax techniques are described. A unified general formulation and solution for the LQG and minimax approaches, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf. The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

NASA NTRS1999

Predicted Aerodynamic Characteristics of a NACA 0015 Airfoil Having a 25% Integral-Type Trailing Edge Flap

Using the two-dimensional ARC2D Navier-Stokes flow solver analyses were conducted to predict the sectional aerodynamic characteristics of the flapped NACA-0015 airfoil section. To facilitate the analyses and the generation of the computational grids, the airfoil with the deflected trailing edge flap was treated as a single element airfoil with no allowance for a gap between the flap's leading edge and the base of the forward portion of the airfoil. Generation of the O-type computational grids was accomplished using the HYGRID hyperbolic grid generation program. Results were obtained for a wide range of Mach numbers, angles of attack and flap deflections. The predicted sectional lift, drag and pitching moment values for the airfoil were then cast in tabular format (C81) to be used in lifting-line helicopter rotor aerodynamic performance calculations. Similar were also generated for the flap. Mathematical expressions providing the variation of the sectional lift and pitching moment coefficients for the airfoil and for the flap as a function of flap chord length and flap deflection angle were derived within the context of thin airfoil theory. The airfoil's sectional drag coefficient were derived using the ARC2D drag predictions for equivalent two dimensional flow conditions.

Hassan, Ahmed↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design, Analysis and Wind Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using (1) classical, (2) linear quadratic Gaussian (LQG), and (3) minimax techniques are described. A unified general formulation and solution for the LQG and minimax approaches, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

NASA NTRS1999

The Effects of Buoyancy and Dilution on the Structure and Lift-off of Coflow Laminar Diffusion Flames

The ability to predict the coupled effects of complex transport phenomena with detailed chemical kinetics in diffusion flames is critical in the modeling of turbulent reacting flows and in understanding the processes by which soot formation and radiative transfer take place. In addition, an understanding of the factors that affect flame extinction in diffusion flames is critical in the suppression of fires and in improving engine efficiency. The goal of our characterizations of coflow laminar diffusion flames is to bring to microgravity the multidimensional diagnostic tools available in normal gravity, and in so doing provide a broader understanding of the successes and limitations of current combustion models. This will lead to a more detailed understanding of the interaction of convection, diffusion and chemistry in both buoyant and nonbuoyant environments. As a sensitive marker of changes in the flame shape, the number densities of excited-state CH (A(exp 2)delta, denoted CH*), and excited-state OH (A(exp 2)Sigma, denoted OH*) are measured in mu-g and normal gravity. Two-dimensional CH* and OH* number densities are deconvoluted from line-of-sight chemiluminescence measurements made on the NASA KC-135 reduced-gravity aircraft. Measured signal levels are calibrated, post-flight, with Rayleigh scattering. Although CH* and OH* kinetics are not well understood, the CH*, OH*, and ground-state CH distributions are spatially coincident in the flame anchoring region. Therefore, the ground-state CH distribution, which is easily computed, and the readily measured CH*/OH* distributions can be used to provide a consistent and convenient way of measuring lift-off height and flame shape in the diffusion flame under investigation. Given that the fuel composition affects flame chemistry and that buoyancy influences the velocity profile of the flow, we have the opportunity to computationally and experimentally study the roles of fluids and chemistry. In performing this microgravity study, improvements to the computational model have been made and new calculations performed for a range of gravity and flow conditions. Furthermore, modifications to the experimental approach were required as a consequence of the constraints imposed by existing microgravity facilities. Results from the computations and experiments are presented in the following sections.

Walsh, Kevin T.↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design, Analysis and Wind-Tunnel Results

Mukhopadhyay, Vivek↗

NASA NTRS1998

Numerical Simulations of a Lobed Fuel Injector

Numerical modeling of the nonreactive mixing processes associated with a lobed fuel injector in a coflowing air stream is presented. The lobed fuel injector is a device which generates strong streamwise vorticity, producing locally high strain rates which can enhance the molecular mixing of reactants while delaying ignition in a controlled manner. Vortex element modeling is used to simulate flow field evolution and fuel element mixing characteristics for this lobed fuel injector. Quantitative predictions for vorticity generation and qualitative results for streamwise rollup compare well qualitatively with recent experimental investigations of this flow field [Smith et al, Phys. Fluids 9, 667 (1997)]. Parametric studies of the effects of lobe amplitude-to-wavelength ratio, lobe angle, and lobe shape for given flow conditions suggest that geometrical features may be optimized to enhance mixing and control reaction processes.

Strickland, J. H.↗

NASA NTRS1999

Overview of Current Turbine Aerodynamic Analysis and Testing at MSFC

An overview of the current turbine aerodynamic analysis and testing activities at NASA/Marshall Space Flight Center (MSFC) is presented. The presentation is divided into three areas. The first area is the three-dimensional (3D), unsteady Computational Fluid Dynamics (CFD) analysis of the Fastrac turbine. Results from a coupled nozzle, blade, and exit guide vane analysis and from an uncoupled nozzle and coupled blade and exit guide vane will be presented. Unsteady pressure distributions, frequencies, and exit profiles from each analysis will be compared and contrasted. The second area is the testing and analysis of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) turbine with instrumented first stage blades. The SSME HPFTP turbine was tested in air at the MSFC Turbine Test Equipment (TTE). Pressure transducers were mounted on the first stage blades. Unsteady, 3D CFD analysis was performed for this geometry and flow conditions. A sampling of the results will be shown. The third area is a status of the Turbine Performance Optimization task. The objective of this task is to improve the efficiency of a turbine for potential use on a next generation launch vehicle. This task includes global optimization for the preliminary design, detailed optimization for blade shapes and spacing, and application of advanced CFD analysis. The final design will be tested in the MSFC TTE.

Griffin, Lisa W.↗

NASA NTRS1999

Melting Efficiency During Plasma Arc Welding

A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 aluminum. Arc Efficiency was measured calorimetrically and ranged between 48% and 66%. Melting efficiency depends on the weld pool shape. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Higher currents are thought to raise arc pressure and depress the liquid at the bottom of the weld pool causing a more nearly two dimensional heat flow condition.

McClure, J.C.↗

NASA NTRS1999

The Effects of Buoyancy and Dilution on the Structure and Lift-Off of Coflow Laminar Diffusion Flames

The ability to predict the coupled effects of complex transport phenomena with detailed chemical kinetics in diffusion flames is critical in the modeling of turbulent reacting flows and in understanding the processes by which soot formation and radiative transfer take place. In addition, an understanding of those factors that affect flame extinction in diffusion flames is critical in the suppression of fires and in improving engine efficiency. A goal of this work is to bring to microgravity flame studies the detailed experimental and numerical tools that have been used to study ground-based systems. This will lead to a more detailed understanding of the interaction of convection, diffusion and chemistry in a nonbuoyant environment. To better understand these phenomena, experimental and computational studies of a coflow laminar diffusion flame have been carried out. To date, these studies have focused on a single set of flow conditions, in which a nitrogen-diluted methane fuel stream (65% methane by volume) was surrounded by an air coflow, with exit velocities matched at 35 cm/s. Of particular interest is the change in flame shape due to the absence of buoyant forces, as well as the amount of diluent in the fuel stream and the coflow velocity. As a sensitive marker of changes in the flame shape, the number densities of excited-state CH (A(exp 2 delta) denoted CH*), and excited-state OH (A(exp 2 sigma, denoted OH*) are measured. CH* and OH* number densities are deconvoluted from line-of-sight chemiluminescence measurements made on the NASA KC135 reduced-gravity aircraft. Measured signal levels are calibrated, post-flight, with Rayleigh scattering. In extending the study to microgravity conditions, improvements to the computational model have been made and new calculations performed for a range of gravity conditions. In addition, modifications to the experimental approach were required as a consequence of the constraints imposed by existing microgravity facilities. Results from the computations and experiments are presented.

Walsh, Kevin T.↗

NASA NTRS1999

Application of the RNS3D Code to a Circular-Rectangular Transition Duct With and Without Inlet Swirl and Comparison with Experiments

Circular-rectangular transition ducts are used between engine exhausts and nozzles with rectangular cross sections that are designed for high performance aircraft. NASA Glenn Research Center has made experimental investigations of a series of circular-rectangular transition ducts to provide benchmark flow data for comparison with numerical calculations. These ducts are all designed with superellipse cross sections to facilitate grid generation. In response to this challenge, the three-dimensional RNS3D code has been applied to one of these transition ducts. This particular duct has a length-to-inlet diameter ratio of 1.5 and an exit-plane aspect ratio of 3.0. The inlet Mach number is 0.35. Two GRC experiments and the code were run for this duct without inlet swirl. One GRC experiment and the code were also run with inlet swirl. With no inlet swirl the code was successful in predicting pressures and secondary flow conditions, including a pair of counter-rotating vortices at both sidewalls of the exit plane. All these phenomena have been reported from the two GRC experiments. However, these vortices were suppressed in the one experiment when inlet swirl was used; whereas the RNS3D code still predicted them. The experiment was unable to provide data near the sidewalls, the very region where the vortices were predicted.

Cavicchi, Richard H.↗

NASA NTRS1999

Turbulence Model Comparisons for a High-Speed Aircraft

Four turbulence models are described and evaluated for transonic flows over the High-Speed Research/industry baseline configuration known as Reference H by using the thin-layer, upwind, Navier-Stokes solver known as CFL3D. The turbulence models studied are the equilibrium model of Baldwin-Lomax (B-L) with the Degani-Schiff (D-S) modifications, the one-equation Baldwin-Barth (B-B) model, the one-equation Spalart-Allmaras (S-A) model, and Menter's two-equation Shear Stress Transport (SST) model. The flow conditions, which correspond to tests performed in the National Transonic Facility (NTF) at Langley Research Center, are a Mach number of 0.90 and a Reynolds number of 30 x 10 (exp. 6) based on mean aerodynamic chord for angles of attack of 1 deg., 5 deg., and 10 deg. The effects of grid topology and the representation of the actual wind tunnel model geometry are also investigated. Computed forces and surface pressures compare reasonably well with the experimental data for all four turbulence models.

Rivers, Melissa B.↗

NASA NTRS1998

Experiments on Nucleation in Different Flow Regimes

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods. Dilitometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post-processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions. Levitation processing of refractory materials in ultra high vacuum provides an avenue to conduct these kinetic studies on single samples. Two experimental methods have been identified where ultra high vacuum experiments are possible; electrostatic levitation in ground-based experiments and electromagnetic processing in low earth orbit on TEMPUS. Such experiments, reported here, were conducted on zirconium. Liquid zirconium is an excellent solvent and has a high solubility for contaminants contained in the bulk material as well as those contaminants found in the vacuum environment. Oxides, nitrides, and carbides do not exist in the melt, and do not form on the surface of molten zirconium, for the materials and vacuum levels used in this study. Ground-based experiments with electrostatic levitation have shown that the statistical nucleation kinetic experiments are viable and yield results which are consistent with classical nucleation theory. The advantage of low earth orbit experiments is the ability to vary the flow conditions in the liquid prior to nucleation. The put-pose of nucleation experiments in TEMPUS was to examine.

Bayuzick, R. J.↗

NASA NTRS1999

A Design Tool for Liquid Rocket Engine Injectors

A practical design tool for the analysis of flowfields near the injector face has been developed and used to analyze the Fastrac engine. The objective was to produce a computational design tool which was detailed enough to predict the interactive effects of injector element impingement angles and points and the momenta of the individual orifice flows. To obtain a model which could be used to simulate a significant number of individual orifices, a homogeneous computational fluid dynamics model was developed. To describe liquid and vapor sub- and super-critical flows, the model included thermal and caloric equations of state which were valid over a wide range of pressures and temperatures. A homogeneous model was constructed such that the local state of the flow was determined directly, i.e. the quality of the flow was calculated. Such a model does not identify drops or their distribution, but it does allow the flow along the injector face and into the acoustic cavity to be predicted. It also allows the film coolant flow to be accurately described. The initial evaluation of the injector code was made by simulating cold flow from an unlike injector element and from a like-on-like overlapping fan (LOL) injector element. The predicted mass flux distributions of these injector elements compared well to cold flow test results. These are the same cold flow tests which serve as the data base for the JANNAF performance prediction codes. The flux distributions 1 inch downstream of the injector face are very similar; the differences were somewhat larger at further distances from the faceplate. Since the cold flow testing did not achieve good mass balances when integrations across the entire fan were made, the CFD simulation appears to be reasonable alternative to future cold flow testing. To simulate the Fastrac, an RP-1/LOX combustion model must be chosen. This submodel must be relatively simple to accomplish three-dimensional, multiphase flow simulations. Single RP-1 pyrolysis and partial oxidation steps were chosen and the combustion was completed with the wet CO mechanism. Soot was also formed with a single global reaction. To validate the combustion submodel, global data from gas generator tests and from subscale motor test were used to predict qualitatively correct mean molecular weights, temperature, and soot levels. Because such tests do not provide general kinetics rates, the methodology is not necessarily appropriate for other than rocket type flows conditions. Soot predictions were made so that radiation heating to the motor walls can be made. These initial studies of the Fastrac were for a small region close to the injector face and chamber wall which included a segment of the acoustic cavity. The region analyzed includes 11 individual orifice holes to represent the LOL elements and the H2 film coolant holes. Typical results of this simulation are shown in Figure 1. At this point the only available test data to verify the predictions are temperatures measured in the acoustic cavity. These temperatures are in reasonable agreement at about 2000R (1111 K). Future work is expected to include improving the computational efficiency or the CFD model and/or using more computer capacity than the single Pentium PC with which these simulations were made.

Farmer, Richard C.↗

NASA NTRS1999

Airplane Mesh Development with Grid Density Studies

Automatic Grid Generation Wish List Geometry handling, including CAD clean up and mesh generation, remains a major bottleneck in the application of CFD methods. There is a pressing need for greater automation in several aspects of the geometry preparation in order to reduce set up time and eliminate user intervention as much as possible. Starting from the CAD representation of a configuration, there may be holes or overlapping surfaces which require an intensive effort to establish cleanly abutting surface patches, and collections of many patches may need to be combined for more efficient use of the geometrical representation. Obtaining an accurate and suitable body conforming grid with an adequate distribution of points throughout the flow-field, for the flow conditions of interest, is often the most time consuming task for complex CFD applications. There is a need for a clean unambiguous definition of the CAD geometry. Ideally this would be carried out automatically by smart CAD clean up software. One could also define a standard piece-wise smooth surface representation suitable for use by computational methods and then create software to translate between the various CAD descriptions and the standard representation. Surface meshing remains a time consuming, user intensive procedure. There is a need for automated surface meshing, requiring only minimal user intervention to define the overall density of mesh points. The surface mesher should produce well shaped elements (triangles or quadrilaterals) whose size is determined initially according to the surface curvature with a minimum size for flat pieces, and later refined by the user in other regions if necessary. Present techniques for volume meshing all require some degree of user intervention. There is a need for fully automated and reliable volume mesh generation. In addition, it should be possible to create both surface and volume meshes that meet guaranteed measures of mesh quality (e.g. minimum and maximum angle, stretching ratios, etc.).

Cliff, Susan E.↗

NASA NTRS2000

On Flowfield Periodicity in the NASA Transonic Flutter Cascade: Numerical Study - Part 2

The transonic flutter cascade facility at NASA Glenn Research Center was redesigned based on a combined program of experimental measurements and numerical analyses. The objectives of the redesign were to improve the periodicity of the cascade in steady operation, and to better quantify the inlet and exit flow conditions needed for CFD predictions. Part I of this paper describes the experimental measurements, which included static pressure measurements on the blade and endwalls made using both static taps and pressure sensitive paints, cobra probe measurements of the endwall boundary layers and blade wakes, and shadowgraphs of the wave structure. Part II of this paper describes three CFD codes used to analyze the facility, including a multibody panel code, a quasi-three-dimensional viscous code, and a fully three-dimensional viscous code. The measurements and analyses both showed that the operation of the cascade was heavily dependent on the configuration of the sidewalls. Four configurations of the sidewalls were studied and the results are described. For the final configuration, the quasi-three-dimensional viscous code was used to predict the location of mid-passage streamlines for a perfectly periodic cascade. By arranging the tunnel sidewalls to approximate these streamlines, sidewall interference was minimized and excellent periodicity was obtained.

Chima, Rodrick V.↗

NASA NTRS1999

Turbulence Model Comparisons and Reynolds Number Effects Over a High-Speed Aircraft at Transonic Speeds

This paper gives the results of a grid study, a turbulence model study, and a Reynolds number effect study for transonic flows over a high-speed aircraft using the thin-layer, upwind, Navier-Stokes CFL3D code. The four turbulence models evaluated are the algebraic Baldwin-Lomax model with the Degani-Schiff modifications, the one-equation Baldwin-Barth model, the one-equation Spalart-Allmaras model, and Menter's two-equation Shear-Stress-Transport (SST) model. The flow conditions, which correspond to tests performed in the NASA Langley National Transonic Facility (NTF), are a Mach number of 0.90 and a Reynolds number of 30 million based on chord for a range of angle-of-attacks (1 degree to 10 degrees). For the Reynolds number effect study, Reynolds numbers of 10 and 80 million based on chord were also evaluated. Computed forces and surface pressures compare reasonably well with the experimental data for all four of the turbulence models. The Baldwin-Lomax model with the Degani-Schiff modifications and the one-equation Baldwin-Barth model show the best agreement with experiment overall. The Reynolds number effects are evaluated using the Baldwin-Lomax with the Degani-Schiff modifications and the Baldwin-Barth turbulence models. Five angles-of-attack were evaluated for the Reynolds number effect study at three different Reynolds numbers. More work is needed to determine the ability of CFL3D to accurately predict Reynolds number effects.

Rivers, Melissa B.↗