ALBERT

Description: New programs are forcing American propulsion system designers into unfamiliar territory. For instance, industry s answer to the cost and reliability goals set out by the Next Generation Launch Technology Program are engine concepts based on the Oxygen- Rich Staged Combustion Cycle. Historical injector design tools are not well suited for this new task. The empirical correlations do not apply directly to the injector concepts associated with the ORSC cycle. These legacy tools focus primarily on performance with environment evaluation a secondary objective. Additionally, the environmental capability of these tools is usually one-dimensional while the actual environments are at least two- and often three-dimensional. CFD has the potential to calculate performance and multi-dimensional environments but its use in the injector design process has been retarded by long solution turnaround times and insufficient demonstrated accuracy. This paper has documented the parallel paths of program support and technology development currently employed at Marshall Space Flight Center in an effort to move CFD to the forefront of injector design. MSFC has established a long-term goal for use of CFD for combustion devices design. The work on injector design is the heart of that vision and the Combustion Devices CFD Simulation Capability Roadmap that focuses the vision. The SRL concept, combining solution fidelity, robustness and accuracy, has been established as a quantitative gauge of current and desired capability. Three examples of current injector analysis for program support have been presented and discussed. These examples are used to establish the current capability at MSFC for these problems. Shortcomings identified from this experience are being used as inputs to the Roadmap process. The SRL evaluation identified lack of demonstrated solution accuracy as a major issue. Accordingly, the MSFC view of code validation and current MSFC-funded validation efforts were discussed in some detail. The objectives of each effort were noted. Issues relative to code validation for injector design were discussed in some detail. The requirement for CFD support during the design of the experiment was noted and discussed in terms of instrumentation placement and experimental rig uncertainty. In conclusion, MSFC has made significant progress in the last two years in advancing CFD toward the goal of application to injector design. A parallel effort focused on program support and technology development via the SCIT Task have enabled the progress.

Description: Numerical solutions of the differential equation obtained from the momentum theorem for the development of a turbulent boundary layer along a thermally insulated surface in two-dimensional and in radial shock-free flow are presented in tabular form for a range of Mach numbers from 0.100 to 10. The solution can be used in a step-wise procedure with any given distribution of favorable pressure gradients and for zero pressure gradients. Solutions are also given for use with moderate adverse pressure gradients. The mean velocity in the boundary layer is approximated by a power-law profile. In view of the stepwise integration methods to be used, the exponent designated the profile shape can be varied along the surface between the integral fraction limits 1/5 and 1/11 through interpolation. Agreement obtained between theoretical and experimental boundary-layer development in a supersonic nozzle at a nominal Mach number of 2 indicates the general validity of the approximations used in the analysis - in particular, the method of extrapolating low-speed skin-friction relations to high Mach number flows. The extrapolation method used assumes that the skin-friction coefficient depend primarily on Reynolds number, provided that the density and the kinematic viscosity are evaluated at surface conditions.

Description: Computational Fluid Dynamics (CFD) is becoming an important component of injector design in the rocket industry. Injector designers who use CFD in the design process need to understand the accuracy level of the particular code being used for certain aspects of the design. This paper represents a recent effort to demonstrate the accuracy of two CFD codes to calculate the wall heat flux for a single element injector. The FDNS and Loci- CHEM codes currently in use at NASA Marshall Space Flight Center were evaluated. The test case was a single shear coaxial element with gaseous oxygen and hydrogen in a chamber instrumented with coaxial heat flux gauges on the chamber wall down the axis. The data were taken at Penn State University. Measured wall temperatures were used as boundary conditions for the CFD calculations. Calculations were compared to experimental data at chamber pressures of 300,450 600, and 750 psia. The accuracy level of both codes was assessed.

Description: Recent experiences in utilizing the global optimization methodology, based on polynomial and neural network techniques for fluid machinery design are summarized. Global optimization methods can utilize the information collected from various sources and by different tools. These methods offer multi-criterion optimization, handle the existence of multiple design points and trade-offs via insight into the entire design space can easily perform tasks in parallel, and are often effective in filtering the noise intrinsic to numerical and experimental data. Another advantage is that these methods do not need to calculate the sensitivity of each design variable locally. However, a successful application of the global optimization method needs to address issues related to data requirements with an increase in the number of design variables and methods for predicting the model performance. Examples of applications selected from rocket propulsion components including a supersonic turbine and an injector element and a turbulent flow diffuser are used to illustrate the usefulness of the global optimization method.

Description: We present views and analysis of the execution of several PVM codes for Computational Fluid Dynamics on a network of Sparcstations, including (a) NAS Parallel benchmarks CG and MG (White, Alund and Sunderam 1993); (b) a multi-partitioning algorithm for NAS Parallel Benchmark SP (Wijngaart 1993); and (c) an overset grid flowsolver (Smith 1993). These views and analysis were obtained using our Automated Instrumentation and Monitoring System (AIMS) version 3.0, a toolkit for debugging the performance of PVM programs. We will describe the architecture, operation and application of AIMS. The AIMS toolkit contains (a) Xinstrument, which can automatically instrument various computational and communication constructs in message-passing parallel programs; (b) Monitor, a library of run-time trace-collection routines; (c) VK (Visual Kernel), an execution-animation tool with source-code clickback; and (d) Tally, a tool for statistical analysis of execution profiles. Currently, Xinstrument can handle C and Fortran77 programs using PVM 3.2.x; Monitor has been implemented and tested on Sun 4 systems running SunOS 4.1.2; and VK uses X11R5 and Motif 1.2. Data and views obtained using AIMS clearly illustrate several characteristic features of executing parallel programs on networked workstations: (a) the impact of long message latencies; (b) the impact of multiprogramming overheads and associated load imbalance; (c) cache and virtual-memory effects; and (4significant skews between workstation clocks. Interestingly, AIMS can compensate for constant skew (zero drift) by calibrating the skew between a parent and its spawned children. In addition, AIMS' skew-compensation algorithm can adjust timestamps in a way that eliminates physically impossible communications (e.g., messages going backwards in time). Our current efforts are directed toward creating new views to explain the observed performance of PVM programs. Some of the features planned for the near future include: (a) ConfigView, showing the physical topology of the virtual machine, inferred using specially formatted IP (Internet Protocol) packets; and (b) LoadView, synchronous animation of PVM-program execution and resource-utilization patterns.

Description: Presentation on intern rotations. Summer 2013 I worked in cryolab and learned about calorimitry testing. Spring 2014 I helped create themalcouple arm for GODU-LH2. Summer 2014 I assisted with hardware failures on GPIM fracture mechanics testing. Summer 2017 I created a qualification test plan and test fixture to test vacuum seal-off valves.

Description: A new, interferometer-based system for measuring thermal expansion to an absolute accuracy of 20 ppb or better at cryogenic temperatures has been developed. Data from NIST Copper SRM 736 measured from room temperature to 15 K will be presented along with data from many other materials including beryllium, ULE, Zerodur, and composite materials. Particular attention will be given to a study by the Space Optics Manufacturing Technology Center (SOMTC) investigating the variability of ULE and beryllium materials used in the AMSD program Approximately 20 samples of each material, tested from room temperature to below 30 K are compared as a function of billet location.

Description: In support of the development of a zero gravity pressure control capability for liquid hydrogen, testing was conducted at the Marshall Space Flight Center using the Multipurpose Hydrogen Test Bed (MHTB) to evaluate the effects of helium pressurant on the performance of a spray bar thermodynamic vent system (TVS). Fourteen days of testing was performed in August - September 2005, with an ambient heat leak of about 70-80 watts and tank fill levels of 90%, 50%, and 25%. The TVS successfully controlled the tank pressure within a +/- 3.45 kPa (+/- 0.5 psi) band with various helium concentration levels in the ullage. Relative to pressure control with an "all hydrogen" ullage, the helium presence resulted in 10 to 30 per cent longer pressure reduction durations, depending on the fill level, during the mixing/venting phase of the control cycle. Additionally, the automated control cycle was based on mixing alone for pressure reduction until the pressure versus time slope became positive, at which time the Joule-Thomson vent was opened. Testing was also conducted to evaluate thermodynamic venting without the mixer operating, first with liquid then with vapor at the recirculation line inlet. Although ullage stratification was present, the ullage pressure was successfully controlled without the mixer operating. Thus, if vapor surrounded the pump inlet in a reduced gravity situation, the ullage pressure can still be controlled by venting through the TVS Joule Thomson valve and heat exchanger. It was evident that the spray bar configuration, which extends almost the entire length of the tank, enabled significant thermal energy removal from the ullage even without the mixer operating. Details regarding the test setup and procedures are presented in the paper. 1

Description: A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci-CHEM CFD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid was used and then locally refined to demonstrate grid convergence. Solutions were obtained with three variations of the k-omega turbulence model.

Description: In designing systems for the long-term storage of cryogens in low gravity space environments, one must consider the effects of thermal stratification on excessive tank pressure that will occur due to environmental heat leakage. During low gravity operations, a Thermodynamic Venting System (TVS) concept is expected to maintain tank pressure without propellant resettling. The TVS consists of a recirculation pump, Joule-Thomson (J-T) expansion valve, and a parallel flow concentric tube heat exchanger combined with a longitudinal spray bar. Using a small amount of liquid extracted by the pump and passing it though the J-T valve, then through the heat exchanger, the bulk liquid and ullage are cooled, resulting in lower tank pressure. A series of TVS tests were conducted at the Marshall Space Flight Center using liquid nitrogen as a liquid oxygen simulant. The tests were performed at fill levels of 90%, 50%, and 25% with gaseous nitrogen and helium pressurants, and with a tank pressure control band of 7 kPa. A transient one-dimensional model of the TVS is used to analyze the data. The code is comprised of four models for the heat exchanger, the spray manifold and injector tubes, the recirculation pump, and the tank. The TVS model predicted ullage pressure and temperature and bulk liquid saturation pressure and temperature are compared with data. Details of predictions and comparisons with test data regarding pressure rise and collapse rates will be presented in the final paper.