ALBERT

Description: As a result of high cycle fatigue, hydrogen embrittlement, and extended engine use, it was observed in testing that the trailing edge on the first stage nozzle plug in the High Pressure Oxygen Turbopump (HPOTP) could detach. The objective was to predict the trajectories followed by particles exiting the turbine. Experiments had shown that the heat exchanger soils, which lie downstream of the turbine, would be ruptured by particles traveling in the order of 360 ft/sec. An axisymmetric solution of the flow was obtained from the work of Lin et. al., who used INS3D to obtain the solution. The particle trajectories were obtained using the method of de Jong et. al., which employs Lagrangian tracking of the particle through the Eulerian flow field. The collision parameters were obtained from experiments conducted by Rocketdyne using problem specific alloys, speeds, and projectile geometries. A complete 3-D analysis using the most likely collision parameters shows maximum particle velocities of 200 ft/sec. in the heat exchanger region. Subsequent to this analysis, an engine level test was conducted in which seven particles passed through the turbine but no damage was observed on the heat exchanger coils.

Description: Under the present effort an experiment rig has been constructed, an instrumentation package developed and a series of mean and rms velocity and pressure measurements made in a turbopump which modelled the first stage of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump. The rig was designed so as to allow initial experiments with a single configuration consisting of a bell-mouth inlet, a flight impeller, a vaneless diffuser and a volute. Allowance was made for components such as inlet guide vanes, exit guide vanes, downstream pumps, etc. to be added in future experiments. This flexibility will provide a clear baseline set of experiments and allow evaluation in later experiments of the effect of adding specific components upon the pump performance properties. The rotational speed of the impeller was varied between 4260 and 7680 rpm which covered the range of scaled SSME rotation speeds when due allowance is made for the differing stagnation temperature, model to full scale. The results at the inlet obtained with rotational speeds of 4260, 6084 and 7680 rpm showed that the axial velocity at the bell-mouth inlet remained roughly constant at 2.2 of the bulk velocity at the exit of the turbopump near the center of the inlet, but it decreased rapidly with increasing radius at all three speeds. Reverse flow occurred at a radius greater than 0.9 R for all three speeds and the maximum negative velocity reduced from 1.3 of the bulk velocity at the exit of the turbopump at 4260 rpm to 0.35 at 7680 rpm, suggesting that operating at a speed closer to the design condition of 8700 rpm improved the inlet characteristics. The reverse flow caused positive prerotation at the impeller inlet which was negligibly small near the center but reached 0.7 of the impeller speed at the outer annulus. The results in the diffuser and the volute obtained at 7680 rpm show that the hub and shroud walls of the diffuser were characterized by regions of transient reverse flow with negative revolution-averaged velocity of 8 percent of the maximum forward revolution-averaged velocity at the center of the diffuser passage near the shroud wall.

Description: An Eulerian-Lagrangian two-phase approach was adopted to model the multi-phase reacting internal flow in a solid rocket with a metalized propellant. An Eulerian description was used to analyze the motion of the continuous phase which includes the gas as well as the small (micron-sized) particulates, while a Lagrangian description is used for the analysis of the discrete phase which consists of the larger particulates in the motor chamber. The particulates consist of Al and Al2O3 such that the particulate composition is 100 percent Al at injection from the propellant surface with Al2O3 fraction increasing due to combustion along the particle trajectory. An empirical model is used to compute the combustion rate for agglomerates while the continuous phase chemistry is treated using chemical equilibrium. The computer code was used to simulate the reacting flow in a solid rocket motor with an AP/HTPB/Al propellant. The computed results show the existence of an extended combustion zone in the chamber rather than a thin reaction region. The presence of the extended combustion zone results in the chamber flow field and chemical being far from isothermal (as would be predicted by a surface combustion assumption). The temperature in the chamber increases from about 2600 K at the propellant surface to about 3350 K in the core. Similarly the chemical composition and the density of the propellant gas also show spatially non-uniform distribution in the chamber. The analysis developed under the present effort provides a more sophisticated tool for solid rocket internal flow predictions than is presently available, and can be useful in studying apparent anomalies and improving the simple correlations currently in use. The code can be used in the analysis of combustion efficiency, thermal load in the internal insulation, plume radiation, etc.

Description: Experiments are being conducted to gain an understanding of the physics of rim scale cavity ingestion in a turbine stage with the high-work, single-stage characteristics envisioned for Advanced Subsonic Transport (AST) aircraft gas turbine engines fo the early 21st century. Initial experimental measurements to be presented include time-averaged turbine rim cavity and main gas path static pressure measurements for rim seal coolant to main gas path mass flow ratios between 0 and 0.02. The ultimate objective of this work is develop improved rim seal design concepts for use in modern high-work, single sage turbines n order to minimize the use of secondary coolant flow. Toward this objective the time averaged and unsteady data to be obtained in these experiments will be used to 1) Quantify the impact of the rim cavity cooling air on the ingestion process. 2) Quantify the film cooling benefits of the rim cavity purge flow in the main gas path. 3) Quantify the impact of the cooling air on turbine efficiency. 4) Develop/evaluate both 3D CFD and analytical models of the ingestion/cooling process.

Description: An analysis of Space Shuttle Main Engine high-pressure oxygen turbopump nozzle plug trajectories has been performed, using a Lagrangian method to track nozzle plug particles expelled from a turbine through a high Reynolds number flow in a turnaround duct with turning vanes. Axisymmetric and parametric analyses reveal that if nozzle plugs exited the turbine they would probably impact the LOX heat exchanger with impact velocities which are significantly less than the penetration velocity. The finding that only slight to moderate damage will result from nozzle plug failure in flight is supported by the results of a hot-fire engine test with induced nozzle plug failures.

Description: A multidimensional implicit Navier-Stokes analysis which uses numerical solution of ensemble-averaged Navier-Stokes equations in a nonorthogonal bodyfitted cylindrical-polar coordinate system has been applied to simulation of the internal flow field in solid-propellant rocket motor chambers with segment joints. The calculation procedure incorporates a two-equation (k-epsilon) turbulence model and utilizes a consistently split, linearized block-implicit algorithm for numerical solution of the governing equations. Computations performed to simulate the axisymmetric flow field in the vicinity of the aft field joint in the Space Shuttle SRB using 14,725 grid points show the presence of a region of reversed axial flow near the downstream edge of the slot. Calculations were also performed for two cases involving asymmetric three-dimensional flow in the vicinity of the aft field joint in the SRB using 721,525 grid points to estimate circumferential velocities and pressure gradients at the joint.

Description: A combined Eulerian-Lagrangian analysis, which combines a linearized block implicit Navier-Stokes analysis for the continuous phase with a Lagrangian analysis for the motion of the droplet phase to simulate evaporating two-phase flows, has been developed. A unique aspect of this analysis is that the Lagrangian equations for the droplet motion have been transformed into the Eulerian computational space using coordinate transformation resulting in better computational efficiency. Use of the present implicit procedure for the continuous phase makes it possible to efficiently use a locally highly refined mesh. The coupling of the continuous phase and the droplet phase analyses is such that it allows the use of convergence acceleration techniques for steady-state problems, as well as making it possible to simulate transient flows. A rapidly evaporating two-phase flow caused by spray of liquid nitrogen in gaseous nitrogen has been used as a test problem to demonstrate the computer code using this analysis.

Description: A multidimensional implicit Navier-Stokes analysis that uses numerical solution of the ensemble-averaged Navier-Stokes equations in a nonorthogonal, body-fitted, cylindrical coordinate system has been applied to the simulation of the steady mean flow in solid propellant rocket motor chambers. The calculation procedure incorporates a two-equation (k-epsilon) turbulence model and utilizes a consistently split, linearized block-implicit algorithm for numerical solution of the governing equations. The code was validated by comparing computed results with the experimental data obtained in cylindrical-port cold-flow tests. The agreement between the computed and experimentally measured mean axial velocities is excellent. The axial location of transition to turbulent flow predicted by the two-equation (k-epsilon) turbulence model used in the computations also agrees well with the experimental data. Computations performed to simulate the axisymmetric flowfield in the vicinity of the aft field joint in the Space Shuttle solid rocket motor using 14,725 grid points show the presence of a region of reversed axial flow near the downstream edge of the slot.