The topics presented are covered in viewgraph form. The programmatic objective is to provide a technology base and maintain an institutional capability for continued advances in the development of advanced space propulsion systems to support launch, upper stage, orbit transfer and ascent/descent engines. The technical objectives are to study: (1) validated design and analytical codes for cryogenic turbopump bearings and seals; (2) design methodologies and diagnostic capabilities for combustion stability; and (3) reduced operations cost, increase life, safety, higher energy density propellants, and in-situ engine concepts

Gorland, S.

English

NASA Technical Reports Server

INTEGRATED TECHNOLOGY PLAN
FOR THE CIVIL SPACE PROGRAM
SPACE R& T BASE; PROPULSION
HIGH THRU,,,qTCHEMICAL
 93-7 svs
S. Gorland
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SPACE R&T BA$ _ROPULSION
HIGH THRUST cHEMICAL
OBJECTIVES
PROGRAMMATIC
Provide a technology base and maintain an insti-
tutional capability for continued advances in the
development of advanced space propulsion
systems to support launch, upper stage, orbit
transfer and ascent/descent engines.
TECHNICAL
Validated design and analytical codes for
cryogenic turbopump bearings and seals.
Full 3D codes for turbopump internal flow and
heat transfer.
Design methodologies and diagnostic capabilities
for combustion stability.
Reduced Operations cost, Increase life, safety.
Higher energy density propellants.
In-situ engine concepts.
RESOURCES ($M)
MILESTONES - (BASE PROGRAM)
FY93 - Demonstrate metallized RP-1 performan(
FY94 - Complete 3D Pump Code Development
FY94 - Complete 1t/O Stability Model
FY94 - Complete Subscale testing of Ceramic
Brush seals.
FYg5. Complete assessment of cryogenic
magnetic bearings.
FY96 - Complete combined cycle analysis.
FY96 - Complete atomic hydrogen engine/feed
system fabrication.
FY97 - Complete generation of tribomaterlals da
base for turbopump bearings.
PARTICIPANTS
PLANNED 3X GUIDELINE
FY91 3.5 3.5
FY92 3.5 3.5
FY93 3.6 4.8
FY94 3.8 6.1
FY95 3.9 7.4
FY96 4.1 8.2
FY97 4.3 9.2
LEWIS RESEARCH CENTER
• High Thrust Chemical
!. PR5-1
https://ntrs.nasa.gov/search.jsp?R=19930074431 2020-03-24T07:40:31+00:00Z
SPACE R&T BASL PROPULSION
HIGH THRUST CHEMICAL
11 ii II
LUNAR AND PLANETARY PROPELLANTS
NEEDS
• Reduce cost of SEI missions
• Validate performance potential of in-situ propellants _
• Demonstrate compatibility between production and propulsion systems
CHALLENGE/_APPROACH ....
• Develop propulsion technology for engines that operate
on propellants produced at the moon and Mars
• Insure englnes operate with high degree of reliability and autonomy
BENEFITS
• Significantly reduce Earth launch-to-orbit mass requirements
• Increase self-sufficiency of planetary bases
• Significantly reduce trip-time for manned Mars missions
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:_I-'ACE R&T BASL PROPULSION
LUNAR AND _ANETARY PROPELLANTR
CURRENT PROGRAM
B Complete Carbon Monoxide/Oxygen sub-scale combustion experiments
Identify technology Issues for dual-fuel engine design
Define Metal/oxygen monopropellant hazardclass]fication
• Establish Metal/Oxygen monopropellant formulation
AUGMENTED PROGRAM
Validate Sub-Scale Metal/Oxygen monopropellant combustion
• Demonstrate Carbon Monoxide/Oxygen engine at large scale
• Demonstrate capability for Large-batch production of Metal/Oxygen
monopropellant
PR5-2
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Benefits
N/tSA
Lm Reiewch Cerd_
In Situ Provel!ant
A
Utilization
Reduces Earth Launch
Mass Requirements
(see figure)
Decreases Mars
Mission Time
Reduces Mission
Complexity
Establishes Self-
Sufficiency of Lunar
and Mars Bases
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0
2O
Lunar Ascent]Descent Vehicle Propulsion
o#°"'i
,If" 33% Savings
• //_'S
"'-0 -°" F_/O2._E _,_gtne
----e--- All02 Lunar Based £nglne
(2010) (2011) (_)!2) r_13) (2o14)
SEI Mission Number
_ear)
32
SPACE R&T BASh. PROPULSION
HIGH THRUST CHEMICAL
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Metallized Propellants:
• Metallized Propellants Offer
Higher Specific Impulse and Higher Propellant Density
Safer Propellants (Gelled)
• Significant Performance Increases Are Possible
Higher Delivered Payload
- Lower Initial Mass in LEO
Oxidizer + Fuel + Metal
02 H 2 AI
02 Hydrocarbon AI
N204 MMH A!
PR5-3
SPACE R&T BASE: OPULSION
HIGH THRUST CHEMICAL i
• Mars:
Metallized Propellants:
Areas of Application and Benefit
PAYLOAD MASSES FOR EXPEDITION MISSION
- Payload To Surface 40
Increased By 20 to 33 Percent c_ --,
IJJ O)
- High Isp Storable NTO/MMH/AI _ °o 30
for Mars Ascent _ _
• _ "' 20
L:nar: ,_
Payload To Surface O ¢ 10
Increased By 3 Percent -J :_>-u)
<O
Robotic Planetary: a. i- 0
Mars Mission
- Enables Fast Missions o_._ _._.¢a
• Earth to Orbit: _
- Liquid Rocket Boosters O_
Added Payload
Safety Enhanced With Gels O
PROPULSION TECHNOLOGY
_-,_
SPACE R&TBAL PROPULSION
HIGH THRUST CHEMICAL
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Current and Needed Technology
for Metallized Propellants=
Current Needed
i
• Combustion/Testing:
Preliminary Subscale Complete Characterization:
0 2/RP-1/AI 0 2/H 2 iA|, 0 2/RP- !/AI
• Rheology"
Preliminary Understanding
of Rheology: RP-1/AI
• Formulatk>n:
Large-Batch Formulation
Complete Understanding:
H2 /AI Gels (60 % AI)
RP-1/AI (60 % AI)
Large-Scale Manufacturing
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PR5.4
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SPACE R&T BASE: PROPULSION
HIGH THRUST CHEMICAL
COMBUSTION
TECHNOLOGY REQUIREMENTS
- Develop Atomization, Supercritical Vaporization, Mixing Models
- Develop Damping Device Models
Develop Diagnostics To Make Measurements In The Combustor
Develop Performance & Stability Database
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TECHNOLOGY CHALLENGES
- Designing High Performance Stable Engines
- Reducing The Amount Of Development & Qualification Testing
BENEFITS
Reduced Engine Weight
Increased Engine Design Margin
- Reduced Engine Development Time
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v SPACE R&T BASE: PROPULSION
HIGH THRUST CHEMICAL
AUGMENTED PROGRAM
INJECTOR ATOMIZATION CHARACTERIZATION
- Develop Supercritical Spray Combustion Model
ROCKET ENGINE COMBUSTION DIAGNOSTICS
- Develop Devices To Measure Rocket Combustor Ruld Properties
NEW STABILITY RATING TECHNIQUES
- Develop High Energy Frequency Controlled Technique
PERFORMANCE & STABILITY DATABASE
- Create Standardized Reporting Format & Database
INTEGRATED BAFFLE/CAVITY MODEL
- Develop Hub Baffle & Baffle/Cavity Interaction Model
t_URRENT PROGRAM
SHEAR COAXIAL INJECTOR ATOMIZATION CHARACTERIZATION
- Compare Cold Flow & Hot Fire Atomization Measurements
- Verify Existing Models & Develop New Model If Appropriate
INJECTOR/CHAMBER FREQUENCY COUPUNG INVESTIGATION
- Investigate LOX Tube Resonance Coupling Instability
- Create Validation Database For Model & CFD Code Development
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SPACE R&T BASE 'ROPULSION
HIGH THRUST UHEM!,CAL
Hi
TURBOMACHINERY CODES/TOOLS U
NEEDS
• Model Secondary flows in the turb0machinery of Iiquidpropellant
rocket engines.
• Integrate these models into current design techniques
CHALLENGE/APPROACH
• Reduce the prohibitive CPU time of numerical'simulation
Use approximation techniques until the availability of massively
parallel processing ......
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BENEFITS
Improved turbomachinery reliability, performance and life
• Decreased time and cost of development
PR5-6
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SPACE R&T BASE HOPULSION
HIGH THRUST L;HEMICAL
TURBOMACHINERY CODES/TOOLS
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CURRENT PROGRAM
• Develop alternative approaches to numerically simulate 3D, unsteady
viscous flow in space turbopumps to better predict aerothermal loads and
component efficiencies
AUGMENTED PROGRAM
• Develop parallel processing capability for turbine design
• Develop deep throttling capability for space turbopumps
• Complete unsteady model for analysis of complete pump stage
• Verify aerodynamic performance for unique, space propulsion turbine
blades
SPACE CHEMICAL PROPULSION PROGRAM
Advanced Expander Test Bed (AETB)
Hydrogen Turbine (First Stage)
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Pratt& WhitneySSMEHPFTPSecondVaneSuctionSide
Effectof First BladeLeakageVortexonSecondVaneFlow
shroud
Surface Slreamlines
With Running
Tip Clearance
Without Tip
Clearance
Stagnation Tern )erature
1
SPACE R&T BAs_" :IOPULSION
HIGH THRUST (.;HEMICAL
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BEARINGS
-)
i)
TECHNOLOGY NEEDS:
Validated design codes and methodologies
Advanced materials and coatings__
Improved bearing and bearing damper design
Improved thermohydrodynamic models
IECHNOLO(_Y CHALLENGES:-............... __ _-_
• Measure complete bearing fluid mechanic and thermal properties to
thoroughly validate codes-___ _ =
• Standardize measurement techniques to determine bearing dynamic
coefficients
• l-cl_ _pr0pellanf(:ompatible and wear resistant materials
• Develop bearing designs tolerant to wide 0pera|tng ranges and pump
transients
TECHNOLOGY BENEFITS --_
Longer Life: Increased reliability, improved maintainability, multi-
mission capability ........
Improyed Performance: Higher speeds, greater stiffness &
damping, improved stability
PR5-8
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SPACE R&T BAS," 'ROPULSION
HIGH THRUST _.,HEMICAL
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BEARINGS
CURRENT PROGRAM
• Experimental testing of LH2 Foil Bearings
• Development of Foil Bearing design and performance prediction code
• Development of dynamic coefficients measurement technique
• Development of hydrostatic bearing steady state and dynamic characteristics
code
• Flow visualization experimentsof fluid film bearings for code validation
• Experimental testing of a hybrid magnetic bearing to Identify technical Issues
AUGMENTED PROGRAM
• Demonstration testing of foil bearings in a turbopump
• Experimental testing of LOX foil bearings
• Development of advanced hydrodynamic, hydrostatic and hybrid bearing concepts
• Experimental testing of fluid film bearings to validate codes
• Development of magnetic and superconducting magnetic bearing technology
• Demonstration of magnetic bearings in a turbopump
• Advancement of cryogenic fluid flow and thermal fundamentals to model bearing
thermohydrodynamics (turbulence modeling, two-phase flow, cavitation, Inertia)
• Establishment of tribomatedals designdata base and methodology
SPACE R&T BASL )ROPULSION
HIGH THRUST CHEMICAL
HYBRID MAGNETIC BEARING
PERMANENT MAGNET-_
POLE PIECE-_
ROTOR LAMINATIONS--_ \
\
POSITION SENSOR \
FOR FORWARD
Y-AXI:
;ITION SENSOR
FOR AFT
\ Y-AXIS
ELECTROMAGNET
STATOR
LAMINATIONS
(COIL WINDINGS
NOT SHOWN
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SHAFT-J ....,.,
POSITION SENSOR
FOR AFT
X-AJ(IS
/
\
\
\
\\
\
\
\ \
_- FERROMAGNETICSLEEVE
POSITION SENSOR FOR FORWARD X-AXIS
=" PR5-9
SPACER&TBA_ PROPULSION
HIGHTHRUS1CHEMICAL i
FOIL BEARING PE
OBJECTIVE:
• CHARACTERIZE FOIL BEARING
LOAD CAPACITY AND TORQUE IN
LH2
APPROACH:
• COOPERATIVE AGREEMENT WITH
AIRESEARCH UNDER 1958 SPACE ACT
• AIRESEARCH PROVIDES ANALYSES
CODES AND FIOL BEARING TESTER
• LERC PROVIDES LH? TEST FACILITY
[RFORMANCE IN LH2
JUSTIFICATION
LONG-LIFE, HIGH LOAD CAPACITY
BEARING IS NEEDED FOR CRYOGENIC
TURBOPUMPS
• AIRESEARCH HAS DEMONSTRATED
LOAD CAPACITY OF 200 + psi IN GN2
$1GMIJlll _/
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PROGRAM HIGHLIGHTS:
• ACHIEVED 240 PSI LOAD CAPACITY IN
LH2
• RAN STABLY AT ALL SPEEDS (10-97
KPRM)
• OVER 150 START/CYCLES WITH NO
NOTICEABLE BEARING WEAR
• ACHIEVED 300 PSI LOAD CAPACITY
IN LN2
• ACCUMULATED RUN TIME: 4 HRS IN
LH2 AND S HRS IN LN2
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SPACE R&T BA_ PROPULSION
HIGH THRUST CHEMICAL
-- ii
TURBOP,UMP SEALS TECHNOLOGy
TECHNOLOGY NEEDS;
Be
Longer life
Lower leakage - especially over wide throttling ranges in small
turbopumps
=
Higher pressure capability
Dynamic stability, high shaft speed
Compatible materials
TECHNOLOGY CHALLENGES:
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Low density, wear-resistant materials or material combinations
Low leakage, non-contacting seals
High dynamic response of seals to shaft excursions
Oxygen compatib!? materials
Actively controlling clearance
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TECHNOLOGY BENEFITS:
• Space Basing capability due to improved reliability and
maintainability
• Increased payload by reducing purge gases needed
• Increased component efficiency
• Improved reliability and maintainability
PR5-10
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SPACER&TBASk ROPULSION
HI,GHTHRUST_.H.EMICAL
I
TURBOPUMP SEALS TECHNOLOGY
CURRENTPROGRAM
BRUSH SEALS FOR CRYOGENIC APPLICATIONS(IN-HOUSE)
FABRICATION INITIATED FOR TESTER MODS.
BRUSH SEALS FOR HIGH TEMPERATURE APPLICATIONS (IN-HOUSE)
ACOUIRED TEST RIG FROM THE AIR FORCE.
NUMERICAL, ANALYTICAL, EXPERIMENTAL STUDY OF FLUID DYNAMIC FORCES IN
SEALS (MECHANICAL TECHNOLOGY, INC.)
THREE INDUSTRIAL CODES READY FOR USER EVALUATION
PROPOSED AUGMENTATION
DEFINE AND EXPERIMENTALLYVALIDATE CERAMICBRUSH SEALS
EXPERIMENTALLY VALIDATE ANALYSIS AND DESIGN CODE FOR 2-PHASE
CRYOGENIC SEALS
DESIGN AND DEMONSTRATE ACTIVELY-CONTROLLED OR "SMART" SEALS
FOR AEROSPACE APPLICATIONSAND DEVELOPTHE NECESSARY ANALYSIS
AND DESIGN TOOLS
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A TYPICAL BRUSH SEAL
iHER
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• • |
,,-, PR5-11
Space R & ,"'-'_se: Propulsion ('-"
High Thrust Chemical
Systems Analysis and Engine Cycles
J
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• Technical Needs
Higher Performance
• Combined Cycle •
• Altitude-Compensating Nozzles •
Full-Flow Staged-Combustion Cycle
High-Mixture-Ratio Operation
Optimization of Coolant-Side Heat Transfer
• Technical Challenges
• Higher Gas-Gas Injector • High-Aspect-Ratio Cooling Channel
Performance Database
• Combined-Cycle System • Mixture Ratio Control
Integration ' __--....... _ .... !-: :-
• Technical Benef'dx
• Higher Performance •
• Simpler Subsystems
Less Severe Operating Conditions
Enhanced Heat Transfer
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bpace K & "l "--"se: Propulsion
High Thr_ Chemical
a= m
- Sysie_ Analysis and Engine Cycles
Altitude-Compensating Nozzles
-- Database on most promising concepts ._ .....
High-Mixture-Ratio Operation
=_ Capability to Operate at High Mixture Ratio Reliably
....... _ :_.Z_-_Z_7__7=- ....... =7_ - _ = ::; . - :
• High-Aspect-Ratio Cooling Channels .................. :
,- Database for Future Designs
• Combined-Cycle Engine ........... -:
=* Engine Conceptl'Sat Uses Both Air and Oxygen as Oxidizer
• Full-Flow Staged-Combustion Cycle
Development of Technology for Gas-Gas Injection and Ox-Rich Preburner
• Liquid-Air Rocket
-* Technology to use Liquefied Air as a Propellant
• CFD Modelling of Coolant Flow in Coolant Passages
CFD Model
PR5-12
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SPACE R&T BAS. PROPULSION
HIGH THRUST.CHEMICAL
_SUMMARY
TECHNICAL CHALLENGE
• Long life turbopump components.
• Improved stability and performance of combustion devices.
• Reduced launch mass and cost, enabling SEI missions.
APPROACH
• Validated models, codes and algorithms for component design and analysis.
• Develop benchmark data for supercritical spray dynamics.
• Evaluate advanced turbomachinery sub-components (seals and bearings) design
concepts.
• System and cycle analysis for design optimization.
• Fundamental combustion research and material characterization.
PAYOFF
• Improved life, durability, performance and safety in the evolution of high thrust
chemical propulsion systems, e.g., SSME and liquid rocket boosters, through
advanced concepts and methodologies.
• Reduce SEI costs.
RELATIONSHIP TO FOCUSED ACTIVITIES AND OTHER PROGRAMS
Develop fundamental technologies in direct support of earth-to-orbit, orbit transfer
and upper stage propulsion programs. Efforts are coordinated with other
Centers and DOD as appropriate.
TECHNOLOGY CONTRIBUTIONS
Expertise and technology in turbomachinery code development utilized by ATD and
i NLS designers.
Combustion stability methodology applied to MSFC TTB and RCS thrusters at JSC.
_-- PR5-13
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Space R/T base: Propulsion (high thrust chemical)

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