Numerical simulation of a methane-oxygen rotating detonation rocket engine
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Energy & Fuels↗
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3D Printing of Components for the Gas-Discharge Chamber of Electric Rocket Engines
A technology is developed for 3D printing of the large-diameter gas-discharge chambers of electric rocket engines. The material employed is a ceramic composite based on silicon nitride.
36 MATERIALS SCIENCE↗
Numerical Analysis of Combustion Dynamics in a Full-Scale Rotating Detonation Rocket Engine using Large Eddy Simulations
Large eddy simulations (LES) using detailed chemistry and leveraging adaptive mesh refinement (AMR) are performed to gain insights into the combustion dynamics within a full-scale methane-oxygen non-premixed rotating detonation rocket engine (RDRE) employing impinging discrete injection schemes. In particular, a comparative analysis of two operating conditions corresponding to the same global equivalence ratio but different mass flow rates is carried out to investigate the resultant impact on detonation wave characteristics and RDRE global performance. Multiple co-rotating detonation waves with spatially-distributed wave structure and preferential alignment with the inner wall of the annulus (due to asymmetry in fuel distribution) are encountered under both conditions. Both cases exhibit pre-detonation deflagrative burning in the fill region, while one of the cases shows higher susceptibility to backflow into the feed plenums due to lower plenum pressures. Furthermore, heat release analysis shows that the thrust obtained from the RDRE is closely linked to the distribution of total heat release between detonative and deflagrative combustion. On the other hand, combustion efficiency is associated with the fraction of heat release occurring in fuel-rich versus fuel-lean regions within the RDRE.
33 ADVANCED PROPULSION SYSTEMS↗
High Fidelity Simulations of a Methane-Oxygen Rotating Detonation Rocket Engine
The rotating detonation combustor (RDC) is an important realization of pressure gain combustion for practical applications. The RDC system is characterized by a highly unsteady flow field, with multiple reflected pressure waves following the strong detonations and the existence of partially-burnt gases entrained within the detonation annulus during the injector recovery process. While experimental efforts have provided macroscopic properties of an RDC with a given fuel-oxidizer mixture and geometry, limited optical access and reduced lifespan of flow-field diagnostic equipment constrain understanding of the mechanisms that lend to wave stability, controllability, and sustainability. To this end, high-fidelity numerical simulations of the Air Force Research Laboratory (AFRL) methane-oxygen rotating detonation rocket engine (RDRE) are performed to provide detailed insight into the detonation physics and anomalous behavior within the combustor. The results highlight the merit of high-fidelity numerical studies in analyzing the combustion processes and injector dynamics of a complex combustion system. The simulations capture the general wave behavior observed within the experimental studies. Three different operating conditions, with varying global equivalence ratio and system mass flow rate, are considered: (1) baseline configuration, (2) high equivalence ratio, and (3) high mass flow rate. The high mass flow rate case results in increased detonation wave strength whereas the high equivalence ratio results in increased deflagrative heat release. The high equivalence ratio case results in chaotic behavior with two pairs of counter-rotating detonation waves, whereas a single pair of co-rotating waves is observed in the baseline and high mass flow rate cases. Further, parasitic combustion of the reactant mixture ahead of the detonation wave diminishes its strength and reduces propagation speed to approximately 50-60\% of the Chapman-Jouguet (CJ) condition. In this work, a detailed analysis of the detonation wave behavior, injector dynamics, and the statistics of combustion parameters are presented.
Prakash, Supraj↗
Rocket Engine Test System for Development of Novel Propulsion Technologies
A 150 lb f thrust class, modular, bi-propellant, rocket engine/gas-generator and supporting test infrastructure has been developed in a cooperative effort between Sandia National Laboratories and the New Mexico Institute of Mining and Technology’s (NMIMT’s) Energetic Materials Research and Testing Center (EMRTC). This modular test engine design consists of a head end fuel-oxidizer injector, a spark ignition gaseous H 2 /O 2 torch igniter, combustion chamber and nozzle module. This robust design allows for rapid configuration changes as well as economical repair should hardware become damaged in testing. The engine interfaces with a permanently installed pressurizing system capable of delivering liquid nitrous oxide and a variety of liquid fuels for both rocket engine development and propellant performance evaluation. The regulated high pressure systems allow for delivery of liquefied gases above their saturation pressure as well as allowing for high pressure rocket engine/gas-generator operation. The facility test cell houses a 1 ton thrust capacity test stand leaving room for larger scale engine development.
36 MATERIALS SCIENCE↗
Nuclear Physics Made Very, Very Easy
The fundamental approach to nuclear physics was prepared to introduce basic reactor principles to various groups of non-nuclear technical personnel associated with NERVA Test Operations. NERVA Test Operations functions as the field test group for the Nuclear Rocket Engine Program. Nuclear Engine for Rocket Vehicle Application (NERVA) program is the combined efforts of Aerojet-General Corporation as prime contractor, and Westinghouse Astronuclear Laboratory as the major subcontractor, for the assembly and testing of nuclear rocket engines. Development of the NERVA Program is under the direction of the Space Nuclear Propulsion Office, a joint agency of the U. S. Atomic Energy Commission and the National Aeronautics and Space Administration. This report is being reprinted for use in the U. S. Atomic Energy Commission and National Aeronautics and Space Administration educational and technology utilization programs.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Early Lab scientists had questions, Plastic Man gave them answers
He was a willing subject in countless scientific experiments, a superstar of health physics, as well as a favorite photo prop -- and not just around Halloween time. He was Plastic Man. Beginning in the mid-1950s, the Lab (then called Los Alamos Scientific Laboratory) often relied on several life-sized synthetic test subjects to avoid experimenting on people. In the early days of the Laboratory, not much was known about how different radioisotopes interacted with the human body and how much it absorbed from different radiation sources. Answering queries like these is where Plastic Man came in. For example, during the 1950s and 1960s, the Lab was tasked with developing nuclear rockets for space exploration under the Rover Program. One of the concerns was how astronauts might be affected when exposed to radiation from these rocket engines. So, the Lab’s health group set up an experiment in which Plastic Man was placed in close proximity to an experimental Rover nuclear rocket engine. Running experiments like this using Plastic Man kept humans safer. How life-like was he? There were actually two variations of Plastic Man. Both had hard plastic exteriors, but one of the models encased a real human skeleton. They also had movable joints and simulated organs, such as a liver, a spleen, kidneys, lungs and a thyroid. Although Plastic Man in its entirety was used in experiments, much of the data collected were from research conducted inside on these replicated organs. In time, technology advanced and Plastic Man was able to retire from the Lab. He found a new home in 1964 as a display at the Laboratory’s science museum, and is sometimes displayed today in the Bradbury Science Museum in downtown Los Alamos.
63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
On the importance of species immiscibility in mixing-layer dynamics at supercritical pressures
The mixing dynamics of injected propellants is a key factor in determining the ignition performance and combustion-instability response of rocket engines, internal combustion engines, and gas turbines. A key source of uncertainty in the prediction of phase-exchange dynamics is the immiscibility of the injected propellants at supercritical pressure conditions, which induces liquid/vapor phase separation and surface-tension dynamics. While experimental observations indicate the presence of liquid/vapor interfacial structures, this interfacial dynamics is typically neglected in numerical analyses. To address this issue, the objective of the present study is to systematically evaluate the importance of species immiscibility on the phase-exchange dynamics of cryogenic LOX/GH2 mixing layers at typical rocket engine injection conditions. This is accomplished by comparing simulations of (i) a recently developed interface-capturing Regularized-Interface Method (RIM) formulation, and (ii) the commonly employed Diffuse-Interface Method (DIM) formulation. Analysis shows that the interfacial dynamics significantly impact the atomization and mixing of the propellants in the near-injector region, which is not captured by the DIM formulation. The findings of this study extend to other immiscible injection systems, such as LOX/kerosene and hydrocarbon-fuel/air, thereby highlighting the importance of resolving species immiscibility in simulating high-pressure combustion engines.
diffused-interface method↗
Space Nuclear Power Autonomous Control Algorithm and Control Element Test Bed
Nuclear thermal rockets are currently NASA’s preferred option for use in a manned mission to Mars in the 2040s. The communication delay between an Earth ground station and a spacecraft heading toward Mars can be up to 20 min. Therefore, controlling the nuclear rocket engine would require either a full-time reactor operator on the mission or an autonomous control system for the reactor. The latter idea of making space nuclear reactors fully autonomous has drawn more interest from stakeholders, but such an autonomous control system must be rigorously tested and validated before it is certified for human use. The cost of a full ground test for a space nuclear reactor is tremendous, so a nonnuclear mock reactor test bed was created to test and validate control elements and control algorithms for space nuclear reactors. The test bed consists of control element hardware that inputs physical measurement data into a reactor emulator to produce the reactor’s performance under steady-state, transient, and fault conditions. The control element hardware consists of six full-sized control drums equipped with servo drives and motors and is instrumented with optical encoders, resolvers, and torque sensors for drum movement characterization. In addition to the drums, a two-phase flow loop was designed and built to mimic the valves and turbomachinery associated with the propellant flow through a nuclear thermal rocket engine; components such as pressure sensors, flow meters, thermocouples, and tachometers are instrumented throughout the loop to characterize the fluid flow, valve, and turbomachinery behavior of the system. The data from the physical hardware (e.g., drum position, propellant flow rates) are input to a nuclear reactor simulator to determine the actual nuclear reactor parameters, and the data are sent back to a control algorithm to complete the control loop. The ability to conduct numerous tests of the control systems and autonomous algorithms can help validate the instrumentation and control aspects for a space nuclear reactor for every possible fault situation.
Wilson, Brandon↗
Dynamic Nuclear Thermal Rocket and Engine Modeling
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Rader, Jordan↗
Five Theorems of Turbulence and Their Practical Application
Five theorems of turbulence are stated on the basis of experimental and theoretical research. These theorems permit simpler mathematical description of the gas dynamics of viscous, nonsteady, nonequilibrium, and compressible fluxes. Some conclusions are reached regarding the gas dynamics of combustion chambers and nozzles in rocket engines.
42 ENGINEERING↗
Scaling of oxygen-methane reacting coaxial jets using x-ray fluorescence to measure mixture fraction
Stoichiometric mixing length L s of reacting coaxial jet flames is a critical scaling parameter for liquid rocket engine combustors. Previous studies have shown that L s for shear coaxial flames can be scaled like their non-reacting counterparts using a non-dimensional momentum flux ratio J. In addition, stoichiometric mixing lengths of reacting and nonreacting coaxial jets collapse upon a single line by altering J using an effective outer flow gas density. This effective density is calculated from a modified version of the equivalence principle, originally developed by Tacina and Dahm [1, 2] and accounts for the effects of heat release on mixing. However, previous studies also required a second nonphysical scaling constant S c for the reacting jets, which is not predicted by the equivalence principle [3]. It was originally hypothesized that S c is attributed to the limitation of hydroxyl (OH) planar laser-induced fluorescence, which only infers L s . Direct quantitative measurement of conserved scalar fields using conventional optical diagnostics is difficult due to the lack of a tracer that easily fluoresces, survives high temperature oxygen flames, and is not dominated by quenching effects. To measure a conserved scalar field, this work implements x-ray fluorescence of Kr and Ar tracers to obtain quantitative mixture fraction fields. From these mixture fraction fields, stoichiometric mixing lengths for two CH 4 /O 2 flames are calculated and scaled against nonreacting coaxial mixing lengths using the equivalence principle. By directly measuring the stoichiometric mixing length, it is established that the additional constant is a byproduct of the OH measurement technique and the equivalence principle fully captures the scaling. Finally, comparison with high-fidelity simulation of the flame further supports this conclusion. In addition to further strengthening this scaling method, this work represents the first use of x-ray fluorescence to make quantitative conserved scalar measurements in turbulent flames.
33 ADVANCED PROPULSION SYSTEMS↗
Photographic Mitigation Documentation Related to the Engine Assembly and Disassembly Facility, Area 25, Nevada National Security Site, Nye County, Nevada
This letter report provides documentation in partial fulfillment of the mitigation of adverse effects to the Engine Maintenance Assembly and Disassembly (E-MAD) facility, a major component of the Nuclear Rocket Development Station (NRDS) Historic District located in Area 25 of the Nevada National Security Site (NNSS). Construction of the E-MAD facility began in 1962 for the purpose of disassembling and maintaining nuclear-powered rocket engines. Once the building was complete in 1967, the E-MAD facility remained in continuous operation until the nuclear rocket program was terminated in 1973. The mothballed facility was repurposed in 1977 for spent nuclear fuel handling and packaging activities. By the mid-1980s, all activities at the E-MAD facility had ceased (Reno et al. 2019). This submission is intended to comply with Stipulation III.D.1 of the Memorandum of Agreement DE-GM58-20NA25534 between the U.S. Department of Energy and the Nevada State Historic Preservation Officer Regarding Corrective Action Activities and Demolition of the Engine Maintenance Assembly and Disassembly Facility and the Test Cell C Historic District, Major Components of the Nuclear Rocket Development Station Historic District Located in Area 25 at the Nevada National Security Site Nye County (hereafter referred to as the MOA). Stipulation III.D.1 states the U.S. Department of Energy (DOE) will submit the existing supplementary collection of the large-format, black-and-white photographic prints taken during the 1996 Historic American Engineering Record (HAER) documentation of the E-MAD facility to the Nuclear Testing Archive (NTA), located on the second floor of the Rogers Building at Desert Research Institute (DRI) in Las Vegas, Nevada.
54 ENVIRONMENTAL SCIENCES↗
Numerical Analysis of Wave Characteristics in a Methane-Oxygen Rotating Detonation Engine
Results from the simulation of the U.S. Air Force Research Laboratory methane–oxygen rotating detonation rocket engine from four independent research groups with different flow solvers underpredicted primary detonation wave speeds by a significant margin as compared to experimental values. In a simulation performed by the authors, the average calculated speed of the detonation waves was roughly [Formula: see text] as compared to the experimentally measured value of [Formula: see text]. This paper presents a detailed analysis of the wave characteristics in this simulation to provide a more quantitative understanding of the underlying factors leading to this discrepancy. The results show that weaker counter-rotating shock waves have a significant impact on the behavior of the primary detonation waves. The wave speed of the primary detonation wave is reduced by [Formula: see text] due to collisions with the counter-rotating waves. The presence of these counter-rotating waves also has a strong influence on the flow conditions upstream of the primary detonation waves, as well as the engine heat release rate. In addition, the flow properties upstream of the detonation wave vary significantly in the radial direction. Finally, the subfilter turbulent viscosity is shown to vary radially and with proximity to detonation waves.
Engineering↗
Understanding the role of flow dynamics in thermoacoustic combustion instability
Thermoacoustic combustion instability is one of the most challenging operational issues in several high-performance, low-emissions combustion technologies, including gas turbines, aircraft engines, rockets, and industrial boilers. Driven by the coupling between combustor acoustics and flame heat release rate fluctuations, thermoacoustic combustion instability can lead to reduced operability, increased emissions, and, in the most extreme cases, catastrophic failure of combustor components. The feedback loop between acoustics and combustion is often facilitated by fluid mechanic oscillations, referred to as “velocity coupling,” whereby acoustic oscillations drive flow fluctuations, which in turn create fluctuations in the flame. The character of these fluid mechanic oscillations is highly dependent on the structure of the flow field and the receptivity of the flow to external excitation. Combustor flow fields use features like fluid recirculation and shear to enhance flame holding and reduce emissions, but these are also the same features that can make the flow receptive to acoustic excitation or even drive self-excited oscillations. Here, in this paper, we discuss the basics of thermoacoustic instability with a focus on the role of hydrodynamic oscillations in typical combustor flows. To facilitate this discussion, we explore the hydrodynamic instability characteristics of several key combustor unit flows (wakes, swirling jets, etc.) and show how the hydrodynamic stability of a flow is an important consideration in determining a combustor’s propensity for thermoacoustic oscillations. Several examples of coupling between hydrodynamics and thermoacoustics are discussed to illustrate this important link. The paper concludes by discussing the potential for designing flow fields that are thermoacoustic instability resistant, either through a reduction in the receptivity of the flow or through nonlinear coupling mechanisms by which self-excited flow instabilities can suppress velocity-coupled combustion oscillations.
42 ENGINEERING↗
Phase Relationships in the Carbon–Titanium–Uranium System for Ultra-High Temperature Nuclear Fuels
Carbides of uranium have attracted interest as fuels for nuclear thermal propulsion (NTP) to drive deep-space exploration owing to their attractive thermal and neutronic properties. Optimization of NTP technology, however, requires ultra-high temperature reactor environments to maximize the ratio of thrust to propellant to achieve peak rocket engine efficiency. Incorporation of transition metals into uranium carbides offers a pathway to increase the melting point of carbide fuels to address the operational challenges posed by NTP. Here, a thermodynamic model has been developed to examine the phase relationships in the C–Ti–U system at NTP conditions. Calculated phase relationships at ultra-high temperatures predict a stable (U, Ti)C solid solution. Additionally, experimental work on C–Ti–U synthesis via arc melting has been carried out, providing data on phase constitution and compositions that can be used to further refine the thermodynamic model that has been developed.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Transcritical diffuse-interface hydrodynamics of propellants in high-pressure combustors of chemical propulsion systems
Rocket engines and high-power new generations of gas-turbine jet engines and diesel engines oftentimes involve the injection of one or more reactants at subcritical temperatures into combustor environments at high pressures, and more particularly at pressures higher than those corresponding to the critical points of the individual components of the mixture, which typically range from 13 to 50 bars for most propellants. This class of trajectories in the thermodynamic space has been traditionally referred to as transcritical. However, the fundamental understanding of fuel atomization, vaporization, mixing, and combustion processes at such high pressures remains elusive. In particular, whereas fuel sprays are relatively well characterized at normal pressures, analyses of dispersion of fuel in high-pressure combustors are hindered by the limited experimental diagnostics and theoretical formulations available. The description of the thermodynamics of hydrocarbon-fueled mixtures employed in chemical propulsion systems is complex and involves mixing-induced phenomena, including an elevation of the critical point whereby the coexistence region of the mixture extends up to pressures much larger than the critical pressures of the individual components. As a result, interfaces subject to surface-tension forces may persist in multicomponent systems despite the high pressures, and may give rise to unexpected spray-like atomization dynamics that are otherwise absent in monocomponent systems above their critical point. In this article, the current understanding of this phenomenon is reviewed within the context of propulsion systems fueled by heavy hydrocarbons. Emphasis is made on analytical descriptions at mesoscopic scales of interest for computational fluid dynamics. In particular, a set of modifications of the constitutive laws in the Navier–Stokes equations for multicomponent flows, supplemented with a high-pressure equation of state and appropriate redefinitions of the thermodynamic potentials, are introduced in this work based on an extended version of the diffuse-interface theory of van der Waals. The resulting formulation involves revisited forms of the stress tensor and transport fluxes of heat and species, and enables a description of the mesoscopic volumetric effects induced by transcritical interfaces consistently with the thermodynamic phase diagram of the mixture at high pressures. Additionally, applications of the theory are illustrated in canonical problems, including dodecane/nitrogen transcritical interfaces in non-isothermal systems. The results indicate that a transcritical interface is formed between the propellant streams that persists downstream of the injection orifice over distances of the same order as the characteristic thermal-entrance length of the fuel stream. The transcritical interface vanishes at an edge that gives rise to a fully supercritical mixing layer.
02 PETROLEUM↗
Programming approaches for scalability, performance, and portability of combustion physics codes
Here, this paper presents the process, strategy, and results associated with porting a typical combustion physics flow solver to current state-of-the-art and future massively-parallel computer architectures. Major focus is placed on the distinct algorithmic structure of these types of codes and how it can be integrated with modern programming paradigms for heterogeneous platforms (i.e., distributed many-core systems with accelerators). An end-to-end case study is presented that exemplifies the process in a generic manner, which then serves as a clear guide with respect to the strategy and best practices leading to a robust and adaptable framework that performs well, is durable over time, is portable, and requires minimal human-effort. This end is accomplished beginning with the use of a mature, validated, structured, multiblock code framework optimized for application of both Large Eddy Simulation (LES) and Direct Numerical Simulation (DNS). This code has been ported to a variety of platforms over the past decade, including most recently the Oak Ridge Leadership Computing Facility’s “Summit” Platform. The experience gained on these multiple platforms provides general insights and thus the results presented are not specific to any one code or platform other than the overarching trend toward distributed many-core systems with accelerators in order to move toward exascale performance. The resultant performance and scalability of the ported code is demonstrated on a real-world application; a state-of-the-art rotating detonation rocket engine simulation that matches the complex geometry and boundary conditions imposed as part of a companion experimental campaign.
97 MATHEMATICS AND COMPUTING↗