Computational Plume Modeling of COnceptual ARES Vehicle Stage Tests

The plume-induced environment of a conceptual ARES V vehicle stage test at the NASA Stennis Space Center (NASA-SSC) was modeled using computational fluid dynamics (CFD). A full-scale multi-element grid was generated for the NASA-SSC B-2 test stand with the ARES V stage being located in a proposed off-center forward position. The plume produced by the ARES V main power plant (cluster of five RS-68 LOX/LH2 engines) was simulated using a multi-element flow solver - CRUNCH. The primary objective of this work was to obtain a fundamental understanding of the ARES V plume and its impingement characteristics on the B-2 flame-deflector. The location, size and shape of the impingement region were quantified along with the un-cooled deflector wall pressures, temperatures and incident heating rates. Issues with the proposed tests were identified and several of these addressed using the CFD methodology. The final results of this modeling effort will provide useful data and boundary conditions in upcoming engineering studies that are directed towards determining the required facility modifications for ensuring safe and reliable stage testing in support of the Constellation Program

Three-dimensional solidification and melting using magnetic field control

A new two-fluid mathematical model for fully three dimensional steady solidification under the influence of an arbitrary acceleration vector and with or without an arbitrary externally applied steady magnetic field have been formulated and integrated numerically. The model includes Joule heating and allows for separate temperature dependent physical properties within the melt and the solid. Latent heat of phase change during melting/solidification was incorporated using an enthalpy method. Mushy region was automatically captured by varying viscosity orders of magnitude between liquidus and solidus temperature. Computational results were obtained for silicon melt solidification in a parallelepiped container cooled from above and from a side. The results confirm that the magnetic field has a profound influence on the solidifying melt flow field thus changing convective heat transfer through the boundaries and the amount and shape of the solid accrued. This suggests that development of a quick-response algorithm for active control of three dimensional solidification is feasible since it would require low strength magnetic fields

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Design Support of the feasibility of operating conditions and procedures is critical in such cases due to the possibility of startup/shutdown transients, moving shock structures, unsteady shock-boundary layer interactions and engine and diffuser unstart modes that can result in catastrophic failure. Analyses of such systems is difficult due to resolution requirements needed to accurately capture moving shock structures, shock-boundary layer interactions, two-phase flow regimes and engine unstart modes. In a companion paper, we will demonstrate with the use of CFD, steady analyses advanced capability to evaluate supersonic diffuser and steam ejector performance in the sub-scale A-3 facility. In this paper we will address transient issues with the operation of the facility especially at startup and shutdown, and assess risks related to afterburning due to the interaction of a fuel rich plume with oxygen that is a by-product of the steam ejectors. The primary areas that will be addressed in this paper are: (1) analyses of unstart modes due to flow transients especially during startup/ignition, (2) engine safety during the shutdown process (3) interaction of steam ejectors with the primary plume i.e. flow transients as well as probability of afterburning. In this abstract we discuss unsteady analyses of the engine shutdown process. However, the final paper will include analyses of a staged startup, drawdown of the engine test cell pressure, and risk assessment of potential afterburning in the facility. Unsteady simulations have been carried out to study the engine shutdown process in the facility and understand the physics behind the interactions between the steam ejectors, the test cell and the supersonic diffuser. As a first approximation, to understand the dominant unsteady mechanisms in the engine test cell and the supersonic diffuser, the turning duct in the facility was removed. As the engine loses power a rarefaction wave travels downstream that disrupts the shock cell structure in the supersonic diffuser. Flow from the test cell is seen to expand into the supersonic diffuser section and re-pressurizes the area around the nozzle along with a upstream traveling compression wave that emanates from near the first stage ejectors. Flow from the first stage ejector expands to the center of the duct and a new shock train is formed between the first and second stage ejectors. Both stage ejectors keep the facility pressurized and prevent any large amplitude pressure fluctuations from affecting the engine nozzle. The resultant pressure loads the nozzle experiences in the shutdown process are small

Unsteady Analyses of Valve Systems in Rocket Engine Testing Environments

This paper discusses simulation technology used to support the testing of rocket propulsion systems by performing high fidelity analyses of feed system components. A generalized multi-element framework has been used to perform simulations of control valve systems. This framework provides the flexibility to resolve the structural and functional complexities typically associated with valve-based high pressure feed systems that are difficult to deal with using traditional Computational Fluid Dynamics (CFD) methods. In order to validate this framework for control valve systems, results are presented for simulations of a cryogenic control valve at various plug settings and compared to both experimental data and simulation results obtained at NASA Stennis Space Center. A detailed unsteady analysis has also been performed for a pressure regulator type control valve used to support rocket engine and component testing at Stennis Space Center. The transient simulation captures the onset of a modal instability that has been observed in the operation of the valve. A discussion of the flow physics responsible for the instability and a prediction of the dominant modes associated with the fluctuations is presented

Computing Thermal Effects of Cavitation in Cryogenic Liquids

A computer program implements a numerical model of thermal effects of cavitation in cryogenic fluids. The model and program were developed for use in designing and predicting the performances of turbopumps for cryogenic fluids. Prior numerical models used for this purpose do not account for either the variability of properties of cryogenic fluids or the thermal effects (especially, evaporative cooling) involved in cavitation. It is important to account for both because in a cryogenic fluid, the thermal effects of cavitation are substantial, and the cavitation characteristics are altered by coupling between the variable fluid properties and the phase changes involved in cavitation. The present model accounts for both thermal effects and variability of properties by incorporating a generalized representation of the properties of cryogenic fluids into a generalized compressible-fluid formulation for a cavitating pump. The model has been extensively validated for liquid nitrogen and liquid hydrogen. Using the available data on the properties of these fluids, the model has been shown to predict accurate temperature-depression values

A New Unsteady Model for Dense Cloud Cavitation in Cryogenic Fluids

Contents include the following: Background on thermal effects in cavitation. Physical properties of hydrogen. Multi-phase cavitation with thermal effect. Solution procedure. Cavitation model overview. Cavitation source terms. New cavitation model. Source term for bubble growth. One equation les model. Unsteady ogive simulations: liquid nitrogen. Unsteady incompressible flow in a pipe. Time averaged cavity length for NACA15 flowfield

Analysis of Flame Deflector Spray Nozzles in Rocket Engine Test Stands

The development of a unified tightly coupled multi-phase computational framework is described for the analysis and design of cooling spray nozzle configurations on the flame deflector in rocket engine test stands. An Eulerian formulation is used to model the disperse phase and is coupled to the gas-phase equations through momentum and heat transfer as well as phase change. The phase change formulation is modeled according to a modified form of the Hertz-Knudsen equation. Various simple test cases are presented to verify the validity of the numerical framework. The ability of the methodology to accurately predict the temperature load on the flame deflector is demonstrated though application to an actual sub-scale test facility. The CFD simulation was able to reproduce the result of the test-firing, showing that the spray nozzle configuration provided insufficient amount of cooling

Modeling Unsteady Cavitation and Dynamic Loads in Turbopumps

A computational fluid dynamics (CFD) model that includes representations of effects of unsteady cavitation and associated dynamic loads has been developed to increase the accuracy of simulations of the performances of turbopumps. Although the model was originally intended to serve as a means of analyzing preliminary designs of turbopumps that supply cryogenic propellant liquids to rocket engines, the model could also be applied to turbopumping of other liquids: this can be considered to have been already demonstrated, in that the validation of the model was performed by comparing results of simulations performed by use of the model with results of sub-scale experiments in water. The need for this or a similar model arises as follows: Cavitation instabilities in a turbopump are generated as inlet pressure drops and vapor cavities grow on inducer blades, eventually becoming unsteady. The unsteady vapor cavities lead to rotation cavitation, in which the cavities detach from the blades and become part of a fluid mass that rotates relative to the inducer, thereby generating a fluctuating load. Other instabilities (e.g., surge instabilities) can couple with cavitation instabilities, thereby compounding the deleterious effects of unsteadiness on other components of the fluid-handling system of which the turbopump is a part and thereby, further, adversely affecting the mechanical integrity and safety of the system. Therefore, an ability to predict cavitation- instability-induced dynamic pressure loads on the blades, the shaft, and other pump parts would be valuable in helping to quantify safe margins of inducer operation and in contributing to understanding of design compromises. Prior CFD models do not afford this ability. Heretofore, the primary parameter used in quantifying cavitation performance of a turbopump inducer has been the critical suction specific speed at which head breakdown occurs. This parameter is a mean quantity calculated on the basis of assumed steady-state operation of the inducer; it does not account for dynamic pressure loads associated with unsteady flow caused by instabilities. Because cavitation instabilities occur well before mean breakdown in inducers, engineers have, until now, found it necessary to use conservative factors of safety when analyzing the results of numerical simulations of flows in turbopumps

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively. The Mach Number distribution shows small yet distinct differences between the two cases such as locations of shocks/shock reflections and a slightly different impingement point on the wall of the diffuser from the expansion at the exit of the nozzle. Similarly the temperature distribution indicates different flow recirculation patterns in the test cell. Both cases capture all the essential flow phenomena such as the shock-boundary layer interaction, plume expansion, expansion of the first stage ejectors, mixing between the engine plume and the first stage ejector flow and pressurization due to the first stage ejectors. The final paper will discuss thermal loads on the walls of the diffuser and cooling mechanisms investigated

A Framework for Integrated Component and System Analyses of Instabilities

Instabilities associated with fluid handling and operation in liquid rocket propulsion systems and test facilities usually manifest themselves as structural vibrations or some form of structural damage. While the source of the instability is directly related to the performance of a component such as a turbopump, valve or a flow control element, the associated pressure fluctuations as they propagate through the system have the potential to amplify and resonate with natural modes of the structural elements and components of the system. In this paper, the authors have developed an innovative multi-level approach that involves analysis at the component and systems level. The primary source of the unsteadiness is modeled with a high-fidelity hybrid RANS/LES based CFD methodology that has been previously used to study instabilities in feed systems. This high fidelity approach is used to quantify the instability and understand the physics associated with the instability. System response to the driving instability is determined through a transfer matrix approach wherein the incoming and outgoing pressure and velocity fluctuations are related through a transfer (or transmission) matrix. The coefficients of the transfer matrix for each component (i.e. valve, pipe, orifice etc.) are individually derived from the flow physics associated with the component. A demonstration case representing a test loop/test facility comprised of a network of elements is constructed with the transfer matrix approach and the amplification of modes analyzed as the instability propagates through the test loop