Importance of nozzle geometry to high-pressure gas-dynamic lasers.
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Kuehn, D. M.↗
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Results for “NOZZLES, HIGH-PRESSURE”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Investigation of the Flow Through a Single-stage Two-dimensional Nozzle in the Langley 11-inch Hypersonic Tunnel
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WIND TUNNEL TESTS - NACA - HYPERSONIC (11")↗
High-pressure combustor exhaust emissions with improved air-atomizing and conventional pressure-atomizing fuel nozzles
A high-pressure combustor segment 0.456 meter (18 in.) long with a maximum cross section of 0.153 by 0.305 meter (6 by 12 in.) was tested with specially designed air-atomizing and conventional pressure-atomizing fuel nozzles at inlet-air temperatures of 340 to 755 k (610 deg to 1360 R), reference velocities of 12.4 to 26.1 meters per second (41 to 86 ft/sec), and fuel-air ratios of 0.008 to 0.020. Increasing inlet-air pressure from 4 to 20 atmospheres generally increased smoke number and nitric oxide, but decreased carbon monoxide and unburned hydrocarbon concentrations with air-atomizing and pressure-atomizing nozzles. Emission indexes for carbon monoxide and unburned hydrocarbons were lower at 4, 10, and 20 atmospheres, and nitric oxide emission indexes were lower at 10 and 20 atmospheres with air-atomizing than with pressure-atomizing nozzles.
Ingebo, R. D.↗
Experimental and analytical sonic nozzle discharge coefficients for Reynolds numbers up to 8 x 10 to the 6th power
Sonic discharge coefficients are obtained for two different geometry flow nozzles using high-pressure nitrogen gas (100 atm) with significant real-gas flow corrections. Throat Reynolds number range extended up to 8 million. Discharge coefficients for both nozzles monotonically increase in value at the high throat Reynolds numbers. The 95-percent confidence band for each nozzle is shown. Analytical discharge coefficients for the continuous and finite radius of curvature nozzle are presented. These analytical results for the laminar and turbulent boundary-layer cases are compared to experimental values for sonic flow. Experimental values are also compared to values calculated from the best empirical curve fit equation for subsonic flow.
Szaniszlo, A. J.↗
High Pressure Hydrogen Nozzle Assembly and Dispenser for Heavy Duty Vehicles (Final Technical Report)
Electricore, Inc. along with partners Bennett Pump Company (Bennett), WEH Technologies, Inc. (WEH), National Renewable Energy Laboratory (NREL), and Quong & Associates, Inc. (QAI) have developed a high-pressure hydrogen nozzle assembly and dispenser for heavy-duty (HD) vehicles. The system was installed, tested and demonstrated at NREL’s Hydrogen Infrastructure Testing and Research Facility (HITRF). The system was designed to have a maximum operating pressure of 87.5 MPa and an approximate average flow rate of 10 kg/min over 10 minutes at fuel temperatures of -40°C. To further develop the specifications and design of the system, the team performed an industry survey to ensure the system met the needs of potential users.
08 HYDROGEN↗
Investigation of a Two-step Nozzle in the Langley 11-inch Hypersonic Tunnel
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AIR FLOW - NOZZLES↗
Use of an air-assisted fuel nozzle to reduce idle emissions of a jt8d engine combustor
Tests were performed at typical engine idle conditions on a single-can JT8D combustor installed in a 24 centimeter (9.45 in.) housing to evaluate the effect of an air-assist nozzle on reducing exhaust emissions. By injecting high-pressure air through the secondary-flow passage of a standard duplex fuel nozzle, it was possible to reduce hydrocarbon emissions from 840 parts per million to 95 parts per million and carbon monoxide emissions from 873 parts per million to 258 parts per million. NOX emissions increased slightly from 18 parts per million to 22 parts per million. An air-assist differential pressure of only 20.1 newtons per square centimeter (29.1 psi) and an airflow rate of only 0.22 percent of the total combustor airflow was required.
Papathakos, L. C.↗
Development of Hydrogen Burner for FT4000® Aeroderivative Engine - Final Report
This report details an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas and ending with improved nozzle concepts for fully robust operation with 100% hydrogen. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) emissions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The design of new fuel/air mixer concepts to improve durability and operability with high hydrogen levels was also completed. A total of eleven new concepts were developed and analyzed, ranging from modifications to the bill-of-materials nozzle to fully clean sheet designs. The concepts were evaluated with non-reacting and reacting flow evaluations to assess the performance of the new hardware designs. Non-reacting tests included Phase Doppler Particle Analysis (PDPA) for droplet size and velocity, mechanical patternation for liquid water flux, and planar laser induced fluorescence (PLIF) with acetone-seeding for gaseous fuel/air mixing characterization. Five scaled candidate fuel nozzle designs, in addition to a scaled bill-of-materials nozzle, were then successfully evaluated in an atmospheric pressure burner rig. The nozzles were evaluated for performance with natural gas, hydrogen/natural gas blends, and pure hydrogen. For 100% hydrogen, the nozzles were evaluated with and without water injection. Optical and infrared imaging of the flame and fuel nozzle was captured. NOx emissions were sampled from fixed emissions probes. The results show measurable differences between the various designs, and the data was used to down-select the two most promising designs to advance to future full pressure rig testing. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water. Two promising nozzle designs have been developed to enable fully robust operation with up to 100% hydrogen. These nozzles require validation at full baseload operating conditions before they can be introduced to the field.
03 NATURAL GAS↗
Combustor exhaust-emissions and blowout-limits with diesel number 2 and Jet A fuels utilizing air-atomizing and pressure-atomizing nozzles
The effect of fuel properties on exhaust emissions and blowout limits of a high-pressure combustor segment is evaluated using a splash-groove air-atomizing fuel injector and a pressure-atomizing simplex fuel nozzle to burn both diesel number 2 and Jet A fuels. Exhaust emissions and blowout data are obtained and compared on the basis of the aromatic content and volatility of the two fuels. Exhaust smoke number and emission indices for oxides of nitrogen, carbon monoxide, and unburned hydrocarbons are determined for comparison. As compared to the pressure-atomizing nozzle, the air-atomizing nozzle is found to reduce nitrogen oxides by 20%, smoke number by 30%, carbon monoxide by 70%, and unburned hydrocarbons by 50% when used with diesel number 2 fuel. The higher concentration of aromatics and lower volatility of diesel number 2 fuel as compared to Jet A fuel appears to have the most detrimental effect on exhaust emissions. Smoke number and unburned hydrocarbons are twice as high with diesel number 2 as with Jet A fuel.
Ingebo, R. D.↗
Effect of nozzle lateral spacing on afterbody drag and performance of twin-jet afterbody models with cone plug nozzles at Mach numbers up to 2.20
Twin-jet afterbody models were investigated by using two balances to measure separately the thrust minus total drag and the afterbody drag at Mach numbers of 0.0 and 0.50 to 2.20 for a constant angle of attack of 0. Translating shroud cone plug nozzles were tested at dry and maximum afterburning power settings with a high-pressure air system used to provide jet total-pressure ratios up to 20.0. Two nozzle lateral spacings were studied by using afterbodies with several interfairing shapes. The close- and wide-spaced afterbodies had identical cross-sectional area distributions when similar interfairings were installed on each. Nozzle cant angles of -5, 0, and 5 degrees were investigated. The results show that the highest overall performance was generally obtained with the close-spaced afterbody, basic interfairings (no base), and uncanted nozzles.
Berrier, B. L.↗
Effect of nozzle lateral spacing on afterbody drag and performance of twin-jet afterbody models with convergent-divergent nozzles at Mach numbers up to 2.2
Twin-jet afterbody models were investigated by using two balances to measure the thrust-minus-total drag and the afterbody drag, separately, at static conditions and at Mach numbers up to 2.2 for an angle of attack of 0 deg. Hinged-flap convergent-divergent nozzles were tested at subsonic-cruise- and maximum-afterburning-power settings with a high-pressure air system used to provide jet-total-pressure ratios up to 20. Two nozzle lateral spacings were studied, using afterbodies with similar interfairing shapes but with different longitudinal cross-sectional area distributions. Alternate, blunter, interfairings with different shapes for the two spacings, which produced afterbodies having identical cross-sectional area progressions corresponding to an axisymmetric minimum wave-drag configuration, were also tested. The results indicate that the wide-spaced configurations improved the flow field around the nozzles, thereby reducing drag on the cruise nozzles; however, the increased surface and projected cross-sectional areas caused an increase in afterbody drag. Except for a slight advantage with cruise nozzles at subsonic speeds, the wide-spaced configurations had the higher total drag at all other test conditions.
Pendergraft, O. C., Jr.↗
Effect of nozzle lateral spacing, engine interfairing shape, and angle of attack on the performance of a twin-jet afterbody model with cone plug nozzles
Twin-jet afterbody models were investigated by using two balances to measure separately the thrust minus total axial force and the afterbody drag at Mach numbers from 0 to 1.3. Angle of attack was varied from minus 2 deg to 8.5 deg. Translating shroud cone plug nozzles were tested at dry-power and maximum-afterburning-power settings with a high-pressure air system used to provide jet total-pressure ratios up to 9.0. Two nozzle lateral spacings were studied by using afterbodies with several interfairing shapes. The close- and wide-spaced afterbodies had identical cross-sectional area distributions when similar interfairings were installed on each. The results show that the highest overall performance was obtained with the close-spaced afterbody and basic interfairings. Increasing angle of attack decreased performance for all configurations and conditions investigated.
Berrier, B. L.↗
Multidimensional Modeling of Mixture Formation in a Hydrogen-Fueled Heavy-Duty Optical Engine With Direct Injection
Hydrogen (H 2 ), as a carbon-free fuel, is considered as one of the most promising solutions to reduce the carbon footprint of hard-to-decarbonize energy and transportation sectors. As such, hydrogen-fueled internal combustion engines (H 2 ICEs) have recently been receiving increasing attention, particularly in applications such as on-road/off-road heavy-duty transport and combined heat and power. The direct injection (DI) of gaseous hydrogen into the combustion chamber offers great potential for achieving high power density and high engine efficiency, while mitigating the risk of backfire and reducing pre-ignition. However, the numerical simulation of H 2 DI system remains a formidable challenge associated with the high computational cost of reproducing compressible supersonic flow and shocks in narrow injector passages and in near-nozzle regions. In general, there is a lack of well-established and validated practices for the modeling of high-pressure H 2 DI in large-bore engines. Here, to this end, this study focuses on computational fluid dynamics (CFD) modeling of the mixture formation process in a heavy-duty optical engine employing a medium-pressure H 2 DI system. Both large eddy simulations (LES) and Reynolds Averaged Navier–Stokes (RANS) simulations are performed and evaluated against optical data. Gaseous hydrogen is injected into the combustion chamber via a centrally located outward opening hollow-cone injector at a pressure of 40 bar. Simulations are carried out for two injection timings, namely, −120 and −60 °CA. The numerical predictions for H 2 distribution in different horizontal and vertical planes during the compression stroke are systematically compared against optical data obtained through planar laser-induced fluorescence (PLIF) measurements. Overall, the LES approach using the Dynamic Structure model is found to have good predictive capabilities for the early jet penetration in terms of length and shape, as well as the later H 2 distributions. However, the unsteady RANS approach with the renormalization group $k - ϵ$ model, which is widely used by industry to model heavy-duty ICEs, significantly underpredicts the H 2 mixing, even at similar mesh resolution to that used in LES. These results indicate that there is a need for the improvement of mixing submodels within the RANS approach when applied to H 2 DI simulations.
LES↗
Thrust Characteristics of Multiple Lifting Jets in Ground Proximity
An investigation has been made to determine the thrust characteristics within ground proximity of a series of models which might represent vertical take-off-and-landing (VTOL) aircraft with multiple exit jet engines exhausting vertically downward beneath a lifting surface. Variations in simulated engine configurations were provided by a series of nozzle insert plugs in which the number of jet exits, located symmetrically on a fixed circle, was varied, or the diameter of the circle was varied for a given number of jet exits. represent lifting surfaces, and high-pressure air was used to simulate jet-engine exhaust. Plywood plates were used to The results of the investigation showed that increasing the number of exits, such that an annular jet configuration was approached, provided more favorable thrust characteristics within ground proximity than any other variation in the geometry of these multiple jets. Tests of a configuration with two nozzles approximating a fan-in-wing VTOL aircraft with fans located at different spanwise locations indicated that the augmentation in thrust within ground proximity was greater for the arrangement with the more inboard location of the nozzles.
Davenport, Edwin E.↗
Microstructural Evolution and Mechanical Properties of LP-DED NASA HR-1 – A Hydrogen Resistant AM Superalloy for Space Propulsion Applications
The National Aeronautics and Space Administration (NASA) has actively pursued metal additive manufacturing (AM) technologies for spaceflight applications since the late 2000s. AM offers transformative advantages in cost, schedule, part consolidation, and design flexibility. Among the various AM techniques, laser powder directed energy deposition (LP-DED) is particularly well suited for fabricating complex geometries with fine feature resolution. In propulsion systems that utilize high-pressure gaseous hydrogen—such as liquid hydrogen rocket engines—hydrogen environment embrittlement (HEE) presents a serious threat to material performance 1,2 . Mechanical property degradation under these conditions can compromise component reliability, especially under cyclic loading. To address this challenge, NASA developed NASA HR-1 (Hydrogen Resistant-1) as a solution for liquid rocket engine components operating in hydrogen-rich environments, using the LP-DED technique 3-9 . A key component in a liquid rocket engine is the exhaust nozzle, which is typically regeneratively cooled (regen) due to the high heat flux. NASA HR-1 was specifically developed for regen nozzle applications using hydrogen as a propellant, providing resistance to HEE, a critical issue for many materials. The AM version of NASA HR-1 was also formulated to achieve high ultimate tensile strength, along with high yield strength and ductility in this environment 5,6 . Low-cycle fatigue (LCF) is another important consideration in nozzle design, as components are expected to endure multiple starts and missions. Additionally, the LP-DED version of the alloy exhibits improved thermal conductivity compared to its wrought counterpart, which benefits nozzle cooling. Overall, NASA HR-1 offers an excellent balance of high strength, HEE resistance, LCF performance, thermal conductivity, and ductility to meet the demanding requirements of channel-cooled nozzles and other components used with hydrogen and other propellants. The LP-DED–processed NASA HR-1 requires several post-processing heat treatment steps to achieve the material properties desirable for its intended application 6 . These steps include stress relief, homogenization, solution annealing, and aging for precipitation hardening. The stress relief treatment mitigates residual stresses accumulated during the LP-DED process and minimizes the potential for distortion. Homogenization, a common step for AM materials, reduces elemental segregation and promotes recrystallization to develop a more equiaxed grain structure. The subsequent solution annealing treatment heats the part to a solid solution temperature to dissolve the undesirable η-phase that forms during cooling from homogenization, followed by rapid cooling to retain an η-phase–free microstructure. Finally, aging promotes precipitation of the strengthening γ′ phase in the alloy. The integration of compositional design and optimized thermal processing enables high-quality LP-DED NASA HR-1 components with excellent microstructural and mechanical stability. Improved chemical and microstructure homogeneity enhances ductility and fatigue resistance—both critical for safe and reliable operation in high-pressure hydrogen environments. NASA has successfully fabricated and hot-fire tested multiple subscale and full-scale channel wall nozzles using LP-DED NASA HR-1 5,6, 9-14 . These efforts included process refinements to support thin-wall construction and various channel geometries. Throughout development, several key observations emerged. After homogenization, the as-built columnar grain structure transforms into a fully equiaxed microstructure. However, subsequent treatments—such as solution annealing and aging—result in changes that are more difficult to track. The grain structure remains largely unchanged, and the γ′ precipitates, typically 5–10 nm in diameter, are beyond the resolution of scanning electron microscopy (SEM). While transmission electron microscopy (TEM) can resolve these fine precipitates, TEM sample preparation is time-consuming and difficult for LP-DED material. As an alternative, differential scanning calorimetry (DSC) offers a useful, qualitative approach to monitor precipitate evolution throughout different stages of heat treatment. The overall goal is to improve the understanding of how heat treatment affects the microstructure and mechanical performance of LP-DED NASA HR-1. This paper presents heat treatment design considerations, microstructural characterization, mechanical testing – including tensile and LCF testing in both air and hydrogen environments.
Superalloy↗
A high-pressure carbon dioxide gasdynamic laser
A carbon dioxide gasdynamic laser was operated over a range of reservoir pressure and temperature, test-gas mixture, and nozzle geometry. A significant result is the dominant influence of nozzle geometry on laser power at high pressure. High reservoir pressure can be effectively utilized to increase laser power if nozzle geometry is chosen to efficiently freeze the test gas. Maximum power density increased from 3.3 W/cu cm of optical cavity volume for an inefficient nozzle to 83.4 W/cu cm at 115 atm for a more efficient nozzle. Variation in the composition of the test gas also caused large changes in laser power output. Most notable is the influence of the catalyst (helium or water vapor) that was used to depopulate the lower vibrational state of the carbon dioxide. Water caused an extreme deterioration of laser power at high pressure (100 atm), whereas, at low pressure the laser for the two catalysts approached similar values. It appears that at high pressure the depopulation of the upper laser level of the carbon dioxide by the water predominates over the lower state depopulation, thus destroying the inversion.
Kuehn, D. M.↗