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Sample records for main engine high

  1. Test results of the highly instrumented Space Shuttle Main Engine

    NASA Astrophysics Data System (ADS)

    McConnaughey, H. V.; Leopard, J. L.; Lightfoot, R. M.

    1992-07-01

    Test results of a highly instrumented Space Shuttle Main Engine (SSME) are presented. The instrumented engine, when combined with instrumented high pressure turbopumps, contains over 750 special measurements, including flowrates, pressures, temperatures, and strains. To date, two different test series, accounting for a total of sixteen tests and 1,667 seconds, have been conducted with this engine. The first series, which utilized instrumented turbopumps, characterized the internal operating environment of the SSME for a variety of operating conditions. The second series provided system-level validation of a high pressure liquid oxygen turbopump that had been retrofitted with a fluid-film bearing in place of the usual pump-end ball bearings. Major findings from these two test series are highlighted in this paper. In addition, comparisons are made between model predictions and measured test data.

  2. Test results of the highly instrumented Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Mcconnaughey, H. V.; Leopard, J. L.; Lightfoot, R. M.

    1992-01-01

    Test results of a highly instrumented Space Shuttle Main Engine (SSME) are presented. The instrumented engine, when combined with instrumented high pressure turbopumps, contains over 750 special measurements, including flowrates, pressures, temperatures, and strains. To date, two different test series, accounting for a total of sixteen tests and 1,667 seconds, have been conducted with this engine. The first series, which utilized instrumented turbopumps, characterized the internal operating environment of the SSME for a variety of operating conditions. The second series provided system-level validation of a high pressure liquid oxygen turbopump that had been retrofitted with a fluid-film bearing in place of the usual pump-end ball bearings. Major findings from these two test series are highlighted in this paper. In addition, comparisons are made between model predictions and measured test data.

  3. Space Transportation Main Engine

    NASA Technical Reports Server (NTRS)

    Monk, Jan C.

    1992-01-01

    The topics are presented in viewgraph form and include the following: Space Transportation Main Engine (STME) definition, design philosophy, robust design, maximum design condition, casting vs. machined and welded forgings, operability considerations, high reliability design philosophy, engine reliability enhancement, low cost design philosophy, engine systems requirements, STME schematic, fuel turbopump, liquid oxygen turbopump, main injector, and gas generator. The major engine components of the STME and the Space Shuttle Main Engine are compared.

  4. High frequency data acquisition system for space shuttle main engine testing

    NASA Technical Reports Server (NTRS)

    Lewallen, Pat

    1987-01-01

    The high frequency data acquisition system developed for the Space Shuttle Main Engine (SSME) single engine test facility at the National Space Technology Laboratories is discussed. The real time system will provide engineering data for a complete set of SSME instrumentation (approx. 100 measurements) within 4 hours following engine cutoff, a decrease of over 48 hours from the previous analog tape based system.

  5. COBRA Main Engine Project

    NASA Technical Reports Server (NTRS)

    Snoddy, Jim; Sides, Steve; Lyles, Garry M. (Technical Monitor)

    2002-01-01

    The COBRA (CO-Optimized Booster for Reusable Applications) project include the following: 1. COBRA main engine project team. 2. COBRA and RLX cycles selected. 3. COBRA proto-type engine approach enables mission success. 4. COBRA provides quick, low cost demo of cycle and technologies. 5. COBRA cycle I risk reduction supports. 6. Achieving engine safety. 6. RLX cycle I risk reduction supports. 7. Flight qualification. 9. Life extension engine testing.

  6. Space Shuttle Main Engine instrumented High Pressure Oxidizer Turbopump technology test bed testing results summary

    NASA Technical Reports Server (NTRS)

    Koelbl, Mary E.

    1993-01-01

    This paper presents the test results from the Space Shuttle Main Engine (SSME) instrumented High Pressure Oxidizer Turbopump (HPOTP). The turbopump was tested on Engine 3001, a highly instrumented engine, in an effort to characterize the turbopump and the engine system. Seven tests, for a total duration of 766 seconds, were performed over a five month time period. The testing was performed at a wide variety of engine conditions. Changes in engine mixture ratio, power level, engine inlet oxidizer pressure, engine inlet fuel pressure, and engine start sequence were made. A discussion of all the HPOTP pressure and temperature data obtained are presented with comparisons to supporting analyses made where applicable. The effect of the various engine conditions on the measured data is addressed. This paper also discusses the challenges that were overcome to obtain the data. The significant instrumentation related problems encountered during the design, fabrication, and testing of this turbopump are summarized. Only those issues that affected the data obtained or the instrumentation itself are discussed. The relevance of the data to other noninstrumented turbomachinery is outlined. Conclusions and recommendations resulting from the test series will be presented.

  7. Space Shuttle Main Engine instrumented High Pressure Oxidizer Turbopump technology test bed testing results summary

    NASA Astrophysics Data System (ADS)

    Koelbl, Mary E.

    1993-06-01

    This paper presents the test results from the Space Shuttle Main Engine (SSME) instrumented High Pressure Oxidizer Turbopump (HPOTP). The turbopump was tested on Engine 3001, a highly instrumented engine, in an effort to characterize the turbopump and the engine system. Seven tests, for a total duration of 766 seconds, were performed over a five month time period. The testing was performed at a wide variety of engine conditions. Changes in engine mixture ratio, power level, engine inlet oxidizer pressure, engine inlet fuel pressure, and engine start sequence were made. A discussion of all the HPOTP pressure and temperature data obtained are presented with comparisons to supporting analyses made where applicable. The effect of the various engine conditions on the measured data is addressed. This paper also discusses the challenges that were overcome to obtain the data. The significant instrumentation related problems encountered during the design, fabrication, and testing of this turbopump are summarized. Only those issues that affected the data obtained or the instrumentation itself are discussed. The relevance of the data to other noninstrumented turbomachinery is outlined. Conclusions and recommendations resulting from the test series will be presented.

  8. Structural Evaluation of a Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump Turbine Blade

    NASA Technical Reports Server (NTRS)

    Abdul-Aziz, Ali

    1996-01-01

    Thermal and structural finite-element analyses were performed on the first high pressure fuel turbopump turbine blade of the space shuttle main engine (SSME). A two-dimensional (2-D) finite-element model of the blade and firtree disk attachment was analyzed using the general purpose MARC (finite-element) code. The loading history applied is a typical test stand engine cycle mission, which consists of a startup condition with two thermal spikes, a steady state and a shutdown transient. The blade material is a directionally solidified (DS) Mar-M 246 alloy, the blade rotor is forged with waspalloy material. Thermal responses under steady-state and transient conditions were calculated. The stresses and strains under the influence of mechanical and thermal loadings were also determined. The critical regions that exhibited high stresses and severe localized plastic deformation were the blade-rotor gaps.

  9. Operational life improvement of SSME high-pressure turbopumps. [Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Hale, J. R.; Wood, B. K.

    1985-01-01

    The current Space Shuttle Main Engine (SSME) Phase I engine demonstrated excellent flight performance but showed limited operational life of the high-pressure fuel turbopumps (HPFTP). Design improvements, supporting analyses, and test results of the SSME Phase II development program are presented. The HPFTP improvements include reduction of turbine operating temperature by 110 to 130 R by reconstructing the seals and the flow contours; modifications of the first- and second-stage turbine blades by recontouring the shank, shotpeening the shank surface, and applying a multilayered, plasma-spray coating to the shank on the downstream side to reduce the effect of the disk coolant; and reduction of the tendency for thermal cracks in the turbine by changing weld configuration to avoid the concentration of stresses in local areas. The high-pressure oxidizer turbopump has been also modified to improve bearing life and to eliminate subsynchronous whirl.

  10. Space shuttle main engine controller

    NASA Technical Reports Server (NTRS)

    Mattox, R. M.; White, J. B.

    1981-01-01

    A technical description of the space shuttle main engine controller, which provides engine checkout prior to launch, engine control and monitoring during launch, and engine safety and monitoring in orbit, is presented. Each of the major controller subassemblies, the central processing unit, the computer interface electronics, the input electronics, the output electronics, and the power supplies are described and discussed in detail along with engine and orbiter interfaces and operational requirements. The controller represents a unique application of digital concepts, techniques, and technology in monitoring, managing, and controlling a high performance rocket engine propulsion system. The operational requirements placed on the controller, the extremely harsh operating environment to which it is exposed, and the reliability demanded, result in the most complex and rugged digital system ever designed, fabricated, and flown.

  11. Rotordynamic Characteristics of the HPOTP (High Pressure Oxygen Turbopump) of the SSME (Space Shuttle Main Engine)

    NASA Technical Reports Server (NTRS)

    Childs, D. W.

    1984-01-01

    Rotational stability of turbopump components in the space shuttle main engine was studied via analysis of component and structural dynamic models. Subsynchronous vibration caused unacceptable migration of the rotor/housing unit with unequal load sharing of the synchronous bearings that resulted in the failure of the High Pressure Oxygen Turbopump. Linear analysis shows that a shrouded inducer eliminates the second critical speed and the stability problem, a stiffened rotor improves the rotordynamic characteristics of the turbopump, and installing damper boost/impeller seals reduces bearing loads. Nonlinear analysis shows that by increasing the "dead band' clearances, a marked reduction in peak bearing loads occurs.

  12. Space shuttle main engine high pressure fuel pump aft platform seal cavity flow analysis

    NASA Technical Reports Server (NTRS)

    Lowry, S. A.; Keeton, L. W.

    1987-01-01

    A general purpose, three-dimensional computational fluid dynamics code named PHOENICS, developed by CHAM Inc., is used to model the flow in the aft-platform seal cavity in the high pressure fuel pump of the space shuttle main engine. The model is used to predict the temperatures, velocities, and pressures in the cavity for six different sets of boundary conditions. The results are presented as input for further analysis of two known problems in the region, specifically: erratic pressures and temperatures in the adjacent coolant liner cavity and cracks in the blade shanks near the outer diameter of the aft-platform seal.

  13. High pressure oxygen turbopump bearing cage stability analyses. [space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Merriman, T. L.; Kannel, J. W.

    1984-01-01

    The low service life of the high pressure oxygen turbopump (HPOTP) bearings used in the space shuttle main engine was examined by use of the Battelle "BASDAP' bearing computer stability model. The dynamic instability of the bearing cage resulted in excessive wear and eventual failure of the unit. By maintaining a cage/race clearance of no more than 0.25 millimeters (0.010 inches), ball/pocket clearance of no less than 0.54 millimeters (0.025 inches), dynamic balancing of the cages, and maintaining adequate lubricant films between the balls and races, cage instability and subsequent bearing degradation can be reduced.

  14. Improved rotor response of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Beatty, R. F.; Hine, M. J.

    1989-01-01

    A means of eliminating the subsynchronous rotor whirl encountered during the development testing of the high-pressure oxygen turbopump of the Space Shuttle Main Engine is proposed. The rotor response is improved by reducing the pump end bearing loads and adding damping between the rotor and housing. In the present method, the impeller annular seals are converted into damping seals and the second rotor critical speed is increased due to the added stiffness of the seal conversion and the stiffening of the rotor shaft.

  15. A study of pump cavitation damage. [space shuttle main engine high pressure oxidizer turbopump

    NASA Technical Reports Server (NTRS)

    Brophy, M. C.; Stinebring, D. R.; Billet, M. L.

    1983-01-01

    The cavitation assessment for the space shuttle main engine high pressure oxidizer turbopump is documented. A model of the flow through the pump was developed. Initially, a computational procedure was used to analyze the flow through the inlet casing including the prediction of wakes downstream of the casing vanes. From these flow calculations, cavitation patterns on the inducer blades were approximated and the damage rate estimated. The model correlates the heavy damage on the housing and over the inducer with unsteady blade surface cavitation. The unsteady blade surface cavitation is due to the large incidence changes caused by the wakes of the upstream vanes. Very high cavitation damage rates are associated with this type of cavitation. Design recommendations for reducing the unsteady cavitation include removing the set of vanes closest to the inducer and modifying the remaining vanes.

  16. Vibration effects of the space shuttle main engine high pressure oxidizer turbopump bellows

    NASA Technical Reports Server (NTRS)

    Harp, J. A.

    1978-01-01

    A welded metal bellows was subjected to a series of vibration tests in a 400 psi oxygen environment to evaluate the effects of the bellows convolutes rubbing on the damper ring in the high pressure oxidizer turbopump of the space shuttle main engine. The bellows was subjected to approximately 2 million cycles at 0.007 in. double amplitude displacement during this series of tests, at a frequency of 400 Hz. Intrumentation of the test specimen revealed no significant heat buildup caused by the rubbing of the bellows convolutes on the damper ring. A final destruct test was made to determine if a fire would result if the bellows ruptured in the 400 psi oxygen environment, thus exposing a fresh metal surface. The vibration input was changed to 0.8 in. double amplitude displacement at 20 Hz to intentionally rupture the bellows. Failure occurred after 2.5 sec; no fire or heat buildup was encountered.

  17. Transient rotordynamic analysis for the space-shuttle main engine high-pressure oxygen turbopump

    NASA Technical Reports Server (NTRS)

    Childs, D. W.

    1974-01-01

    A simulation study was conducted to examine the transient rotordynamics of the space shuttle main engine (SSME) high pressure oxygen turbopump (HPOTP) with the objective of identifying, anticipating, and avoiding rotordynamic problem areas. Simulations were performed for steady state operations at emergency power levels and for critical speed transitions. No problems are indicated in steady state operation of the HPOTP emergency power levels, although the results indicated that a rubbing condition will be experienced during critical speed transition at shutdown, particularly involving rotor deceleration rate and imbalance distribution rubbing at the turbine floating-ring seals. The condition is correctable by either reducing the imbalance at the HPOTP hot gas turbine wheels, or by a more rapid deceleration of the rotor through it critical speed.

  18. Effect of flange bolt preload on Space Shuttle main engine high pressure oxidizer turbopump housing analysis

    NASA Technical Reports Server (NTRS)

    Min, J. B.; Johnston, L. M.; Czekalski, B.

    1991-01-01

    Cracks at the seal fillet flange and the strut pilot groove of primary turbine drain passage of the space shuttle main engine (SSME) high pressure oxidizer turbopump (HPOTP) were observed and reported. Stress information for critical structural components in the SSME under actual conditions is necessary for design and life prediction analysis. However, little information is available about the stress distribution at this location under various combinations of loadings and environments. Thus, a stress analysis was conducted to determine an influence of the various operation and installation loads on the stresses of the HPOTP main mounting flange. To do this, a 3-D finite element model of the HPOTP housing was generated. A fairly comfortable margin of stresses at the flange fillet with respect to the yield stress of Inconel 718 is shown. However, it was revealed that the bending stress arising from the housing flange bolt preloads could significantly affect the stress distribution at the strut pilot groove of primary turbine drain passage in the HPOTP housing. Consequently, the information obtained from the present 3-D analysis results should be useful in guiding the development of the SSME HPOTP.

  19. Space Shuttle Main Engine High Pressure Fuel Turbopump Turbine Blade Cracking

    NASA Technical Reports Server (NTRS)

    Lee, Henry

    1988-01-01

    The analytical results from two-dimensional (2D) and three-dimensional (3D) finite element model investigations into the cracking of Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) first- and second-stage turbine blades are presented. Specifically, the initiation causes for transverse cracks on the pressure side of the firststage blade fir tree lobes and face/corner cracks on the downstream fir tree face of the second-state blade are evaluated. Because the blade material, MAR-M-246 Hf (DS), is highly susceptible to hydrogen embrittlement in the -100 F to 400 F thermal environment, a steady-state condition (full power level = 109 percent) rather than a start-up or shut-down transient was considered to be the most likely candidate for generating a high-strain state in the fir tree areas. Results of the analyses yielded strain levels on both first- and second-stage blade fir tree regions that are of a magnitude to cause hydrogen assisted low cycle fatigue cracking. Also evident from the analysis is that a positive margin against fir tree cracking exists for the planned design modifications, which include shot peening for both first- and second-stage blade fir tree areas.

  20. Load cell verification of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Beatty, R. F.; Hine, M. J.

    1986-01-01

    The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.

  1. The Space Shuttle Main Engine High-Pressure Fuel Turbopump rotordynamic instability problem

    NASA Technical Reports Server (NTRS)

    Childs, D. W.

    1977-01-01

    The SSME (Space Shuttle Main Engine) HPFTP (High-Pressure Fuel Turbopump) has been subject to a rotordynamic instability problem, characterized by large and damaging subsynchronous whirling motion. The original design of the HPFTP (from a rotordynamic viewpoint) and the evolution of the HPFTP subsynchronous whirl problem are reviewed. The models and analysis which have been developed and utilized to explain the HPFTP instability and improve its stability performance are also reviewed. Elements of the rotordynamic model which are discussed in detail include the following: (a) hydrodynamic forces due to seals, (b) internal rotor damping, (c) bearing and casing support stiffness asymmetry, and (d) casing dynamics. The stability and synchronous response characteristics of the following two design alternatives are compared: (a) a 'stiff' symmetric bearing support design and (b) a damped asymmetric stiffness design. With appropriate interstage seal designs, both designs are shown, in theory to provide substantially improved stability and synchronous response characteristics in comparison to the original design. The asymmetric design is shown to have better stability and synchronous response characteristics than the stiffly supported design.

  2. Space Shuttle Era: Main Engines

    NASA Video Gallery

    Producing 500,000 pounds of thrust from a package weighing only 7,500 pounds, the Space Shuttle Main Engines are one of the shining accomplishments of the shuttle program. The success did not come ...

  3. Vibration characteristics of the HPOTP (High Pressure Oxygen Turbopump) of the SSME (Space Shuttle Main Engine)

    NASA Technical Reports Server (NTRS)

    Childs, D. W.; Moyer, D. S.

    1985-01-01

    A review is presented of various rotordynamic problems which have been encountered and eliminated in developing the current flight engines, and continuing subsynchronous problems which are being encountered in developing a 109% power level engine. The basic model for the High Pressure Oxygen Turbopump (HPOTP) of the SSME including the structural dynamic model for the rotor and housing and component models for the liquid and gas seals, turbine-clearance excitation forces, and impeller-diffuser forces are discussed. Results from a linear model are used to examine the synchronous response and stability characteristics of the HPOTP, examining bearing load and stability problems associated with the second critical speed. Various seal modifications are examined and shown to have favorable consequences with respect to bearing reactions and stability.

  4. A model for the space shuttle main engine high pressure oxidizer turbopump shaft seal system

    NASA Technical Reports Server (NTRS)

    Paxson, Daniel E.

    1990-01-01

    A simple static model is presented which solves for the flow properties of pressure, temperature, and mass flow in the Space Shuttle Main Engine pressure Oxidizer Turbopump Shaft Seal Systems. This system includes the primary and secondary turbine seals, the primary and secondary turbine drains, the helium purge seals and feed line, the primary oxygen drain, and the slinger/labyrinth oxygen seal pair. The model predicts the changes in flow variables that occur during and after failures of the various seals. Such information would be particularly useful in a post flight situation where processing of sensor information using this model could identify a particular seal that had experienced excessive wear. Most of the seals in the system are modeled using simple one dimensional equations which can be applied to almost any seal provided that the fluid is gaseous. A failure is modeled as an increase in the clearance between the shaft and the seal. Thus, the model does not attempt to predict how the failure process actually occurs (e.g., wear, seal crack initiation). The results presented were obtained using a FORTRAN implementation of the model running on a VAX computer. Solution for the seal system properties is obtained iteratively; however, a further simplified implementation (which does not include the slinger/labyrinth combination) was also developed which provides fast and reasonable results for most engine operating conditions. Results from the model compare favorably with the limited redline data available.

  5. Space Shuttle Main Engine. Overview

    NASA Astrophysics Data System (ADS)

    Jackson, Eugene D.

    An overview of the Space Shuttle Main Engine (SSME) is presented. The Space Shuttle propulsion system consists of two large solid booster motors, three SSME's, two orbital maneuvering system engines, and 44 reaction control system thrusters. The three SSME's burn liquid hydrogen and liquid oxygen from the external tank and are sequentially started at launch. Engine thrust is throttleable. The major components and some of their key features and operational parameters are outlined. The life and reliability being achieved by the SSME are presented.

  6. Assessment of crack growth in a space shuttle main engine first-stage, high-pressure fuel turbopump blade

    NASA Technical Reports Server (NTRS)

    Abdul-Aziz, Ali

    1993-01-01

    A two-dimensional finite element fracture mechanics analysis of a space shuttle main engine (SSME) turbine blade firtree was performed using the MARC finite element code. The analysis was conducted under combined effects of thermal and mechanical loads at steady-state conditions. Data from a typical engine stand cycle of the SSME were used to run a heat transfer analysis and, subsequently, a thermal structural fracture mechanics analysis. Temperature and stress contours for the firtree under these operating conditions were generated. High stresses were found at the firtree lobes where crack initiation was triggered. A life assessment of the firtree was done by assuming an initial and a final crack size.

  7. Space Shuttle Main Engine Block I engine for STS-70

    NASA Technical Reports Server (NTRS)

    1995-01-01

    A Space Shuttle Main Engine (SSME) hoist prepares to lift the first Block I engine to be installed in an orbiter into the number one position on Discovery while the spaceplane is being prepared for the STS-70 mission in the high bay of Orbiter Processing Facility bay 2. The new engine, SSME No. 2036, features a new high-pressure liquid oxygen turbopump, a two-duct powerhead, a baffleless main injector, a single-coil heat exchange and start sequence modifications. The other two main engines to be used during the liftoff of the STS-70 are of the existing Phase II design.

  8. Vibration characteristics of the HPOTP (High-Pressure Oxygen Turbopump) of the SSME (Space Shuttle Main Engine)

    NASA Technical Reports Server (NTRS)

    Childs, D. W.; Moyer, D. S.

    1984-01-01

    Attention is given to rotor dynamic problems that have been encountered and eliminated in the course of Space Shuttle Main Engine (SSME) development, as well as continuing, subsynchronous problems which are being encountered in the development of a 109-percent power level engine. The basic model for the SSME's High Pressure Oxygen Turbopump (HPOTP) encompasses a structural dynamic model for the rotor and housing, and component models for the liquid and gas seals, turbine clearance excitation forces, and impeller diffuser forces. Linear model results are used to examine the synchronous response and stability characteristics of the HPOTP, with attention to bearing load and stability problems associated with the second critical speed. Differences between linear and nonlinear model results are discussed and explained in terms of simple models. Simulation results indicate that while synchronous bearing loads can be reduced, subsynchronous motion is not eliminated by seal modifications.

  9. Impeller shroud to casing leakage flow simulations in the Space Shuttle Main Engine high pressure fuel pump

    NASA Technical Reports Server (NTRS)

    Sindir, Munir M.

    1987-01-01

    Quasi-three-dimensional Navier-Stokes calculations were carried out for the Space Shuttle Main Engine high-pressure fuel pump to simulate the impeller shroud to casing leakage flow. This flow geometry was modeled as an axisymmetric cavity flow with a stationary surface representing the casing, and a rotating surface denoting the impeller. A 63 x 81-node mesh provided sufficient resolution in the regions of greatest flow variations and reduced the effects of numerical diffusion. The turbulence field was closed with the high Reynolds number form of the k-epsilon model supplemented with wall functions in the vicinity of the walls. Finally, a parametric study quantified the effects of through mass flow changes on this leakage flow.

  10. Cold flow simulation of the alternate turbopump development turbine of the Space Shuttle main engine high pressure fuel turbopump

    NASA Astrophysics Data System (ADS)

    Rutkowski, Richard J.

    1994-03-01

    Completion of the installation at the Naval Postgraduate School of a cold-flow test facility for the turbine of the Space Shuttle Main Engine High Pressure Fuel Turbopump is reported. The article to be tested is the first stage of the Alternate Turbopump Development model designed and manufactured by Pratt & Whitney. The purpose of the facility is to enable the development of non-intrusive flow measurements and comparison of those measurements with numerical simulations. Flow field characteristics of the turbine stator were predicted using a three-dimensional viscous flow code. A sensitivity study was conducted to determine the effect of inlet profile to flow field solution. Recommendations are made for future use of the test facility and validation of the numerical simulation scheme.

  11. Developing acceptance limits for measured bearing wear of the Space Shuttle Main Engine high pressure oxidizer turbopump

    NASA Technical Reports Server (NTRS)

    Genge, Gary G.

    1991-01-01

    The probabilistic design approach currently receiving attention for structural failure modes has been adapted for obtaining measured bearing wear limits in the Space Shuttle Main Engine high-pressure oxidizer turbopump. With the development of the shaft microtravel measurements to determine bearing health, an acceptance limit was neeed that protects against all known faiure modes yet is not overly conservative. This acceptance criteria limit has been successfully determined using probabilistic descriptions of preflight hardware geometry, empirical bearing wear data, mission requirements, and measurement tool precision as an input for a Monte Carlo simulation. The result of the simulation is a frequency distribution of failures as a function of preflight acceptance limits. When the distribution is converted into a reliability curve, a conscious risk management decision is made concerning the acceptance limit.

  12. Space shuttle main engine vibration data base

    NASA Technical Reports Server (NTRS)

    Lewallen, Pat

    1987-01-01

    In order to evaluate Space Shuttle Main Engine (SSME) vibration data without having to constantly replay analog tapes, the SSME Vibration Data Base was developed. This data base contains data that have been digitized at a high sample rate for the entire test duration. It provides quick and efficient recall capabilities for numerious computation and display routines. The data base components are described as well as some of the compution and display features.

  13. Shuttle Main Engine Firing in Gimbal Test

    NASA Technical Reports Server (NTRS)

    1995-01-01

    A close-up view of a Space Shuttle Main Engine during a test at the John C. Stennis Space Center shows how the engine is gimballed, or rotated to evaluate the performance of its components under simulated flight conditions.

  14. Solution of the subsynchronous whirl problem in the high-pressure hydrogen turbomachinery of the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Ek, M. C.

    1978-01-01

    Subsynchronous whirl of the high-pressure fuel turbopump limited operation of the Space Shuttle Main Engine for some months in early 1976. The means by which this problem was successfully attacked is of particular interest to the rotor-dynamics community, not only because this machinery was the highest power-to-weight ratio known (77,000 hp...760 pounds), but because of the multiple forcing functions involved and the means, both analytical and experimental, which were utilized in separating variables, pointing toward successful solutions, and evaluating results. The general means of identifying fundamental characteristics, analyzing data, and conducting computer investigations are delineated. The results of analysis and testing are discussed. Since whirl inception occurs at a shaft speed greater than twice the first system critical, this was increased by stiffening the shaft and bearing supports; the system damping and system stiffness was additionally increased by proper interstage seal design to the extent that the instability threshold is now beyond the operating range.

  15. Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 3A: High pressure oxidizer turbo-pump preburner pump housing stress analysis report

    NASA Technical Reports Server (NTRS)

    Shannon, Robert V., Jr.

    1989-01-01

    The model generation and structural analysis performed for the High Pressure Oxidizer Turbopump (HPOTP) preburner pump volute housing located on the main pump end of the HPOTP in the space shuttle main engine are summarized. An ANSYS finite element model of the volute housing was built and executed. A static structural analysis was performed on the Engineering Analysis and Data System (EADS) Cray-XMP supercomputer

  16. Space transportation main engine reliability and safety

    NASA Technical Reports Server (NTRS)

    Monk, Jan C.

    1991-01-01

    Viewgraphs are used to illustrate the reliability engineering and aerospace safety of the Space Transportation Main Engine (STME). A technology developed is called Total Quality Management (TQM). The goal is to develop a robust design. Reducing process variability produces a product with improved reliability and safety. Some engine system design characteristics are identified which improves reliability.

  17. Space transportation main engine cycle assessment process

    NASA Technical Reports Server (NTRS)

    Mcconnaughey, H. V.; Lyles, G. M.

    1991-01-01

    The Advanced Launch System (ALS) program selection process for a space transportation main engine (STME) power cycle is described in terms of the methodology employed. Low cost, robustness, and high reliability are the primary parameters for engine choice, suggesting simplicity of design and efficient fabrication methods as the crucial characteristics. An evaluation methodology is developed based on the Pugh (1981) process and the King (1989) matrices. The cycle configurations considered are the gas generator (GG), the closed expander, and the open expander. The cycle assessment team determined that the GG cycle is favored by most cycle discriminators, based on an assessment of the characteristics in terms of ALS goals. The lower development risk of the GG-cycle STME is consistent with the goals of the ALS program in terms of reliability and cost efficiency.

  18. Space shuttle main engine: Interactive design challenges

    NASA Technical Reports Server (NTRS)

    Mccarty, J. P.; Wood, B. K.

    1985-01-01

    The operating requirements established by NASA for the SSME were considerably more demanding than those for earlier rocket engines used in the military launch vehicles or Apollo program. The SSME, in order to achieve the high performance, low weight, long life, reusable objectives, embodied technical demands far in excess of its predecessor rocket engines. The requirements dictated the use of high combustion pressure and the staged combustion cycle which maximizes performance through total use of all propellants in the main combustion process. This approach presented a myriad of technical challenges for maximization of performance within attainable state of the art capabilities for operating pressures, operating temperatures and rotating machinery efficiencies. Controlling uniformity of the high pressure turbomachinery turbine temperature environment was a key challenge for thrust level and life capability demanding innovative engineering. New approaches in the design of the components were necessary to accommodate the multiple use, minimum maintenance objectives. Included were the use of line replaceable units to facilitate field maintenance automatic checkout and internal inspection capabilities.

  19. Space Shuttle Main Engine (SSME) Test Firing

    NASA Technical Reports Server (NTRS)

    1981-01-01

    A Space Shuttle Main Engine (SSME) undergoing a full power level 290.04 second test firing at the National Space Technology Laboratories (currently called the Stennis Space Center) in Mississippi. The firings were part of a series of developmental testing designed to increase the amount of thrust available to the Shuttle from its three main engines. The additional thrust allowed the Shuttle to launch heavier payloads into orbit. The Marshall Space Flight Center (MSFC) had management responsibility of Space Shuttle propulsion elements, including the Main Engines.

  20. Space Shuttle Main Engine Test Firing

    NASA Technical Reports Server (NTRS)

    1988-01-01

    A cloud of extremely hot steam boils out of the flame deflector at the A-1 test stand during a test firing of a Space Shuttle Main Engine (SSME) at the John C. Stennis Space Center, Hancock County, Mississippi.

  1. Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 3B: High pressure fuel turbo-pump preburner pump bearing assembly analysis

    NASA Technical Reports Server (NTRS)

    Power, Gloria B.; Violett, Rebeca S.

    1989-01-01

    The analysis performed on the High Pressure Oxidizer Turbopump (HPOTP) preburner pump bearing assembly located on the Space Shuttle Main Engine (SSME) is summarized. An ANSYS finite element model for the inlet assembly was built and executed. Thermal and static analyses were performed.

  2. Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 4: High pressure fuel turbo-pump inlet housing analysis

    NASA Technical Reports Server (NTRS)

    Pool, Kirby V.

    1989-01-01

    The analysis performed on the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) inlet housings is summarized. Three DIAL finite element models were build to aid in assessing the structural life of the welds and fillets at the vanes. Complete results are given.

  3. Space Shuttle Main Engine Public Test Firing

    NASA Technical Reports Server (NTRS)

    2000-01-01

    A new NASA Space Shuttle Main Engine (SSME) roars to the approval of more than 2,000 people who came to John C. Stennis Space Center in Hancock County, Miss., on July 25 for a flight-certification test of the SSME Block II configuration. The engine, a new and significantly upgraded shuttle engine, was delivered to NASA's Kennedy Space Center in Florida for use on future shuttle missions. Spectators were able to experience the 'shake, rattle and roar' of the engine, which ran for 520 seconds - the length of time it takes a shuttle to reach orbit.

  4. Closeup View of the Space Shuttle Main Engine (SSME) 2044 ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Close-up View of the Space Shuttle Main Engine (SSME) 2044 mounted in a SSME Engine Handler in the SSME processing Facility at Kennedy Space Center. This view shows SSME 2044 with its expansion nozzle removed and an Engine Leak-Test Plug is set in the throat of the Main Combustion Chamber in the approximate center of the image, the insulated, High-Pressure Fuel Turbopump sits below that and the Low Pressure Oxidizer Turbopump Discharge Duct sits towards the top of the engine assembly in this view. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  5. Computational fluid dynamics analysis of Space Shuttle main engine multiple plume flows at high-altitude flight conditions

    NASA Technical Reports Server (NTRS)

    Dougherty, N. S.; Holt, J. B.; Liu, B. L.; Johnson, S. L.

    1992-01-01

    Computational fluid dynamics (CFD) analysis is providing verification of Space Shuttle flight performance details and is being applied to Space Shuttle Main Engine Multiple plume interaction flow field definition. Advancements in real-gas CFD methodology that are described have allowed definition of exhaust plume flow details at Mach 3.5 and 107,000 ft. The specific objective includes the estimate of flow properties at oblique shocks between plumes and plume recirculation into the Space Shuttle Orbiter base so that base heating and base pressure can be modeled accurately. The approach utilizes the Rockwell USA Real Gas 3-D Navier-Stokes (USARG3D) Code for the analysis. The code has multi-zonal capability to detail the geometry of the plumes based region and utilizes finite-rate chemistry to compute the plume expansion angle and relevant flow properties at altitude correctly. Through an improved definition of the base recirculation flow properties, heating, and aerodynamic design environments of the Space Shuttle Vehicle can be further updated.

  6. Cold flow testing of the Space Shuttle Main Engine alternate turbopump development high pressure fuel turbine model

    NASA Astrophysics Data System (ADS)

    Gaddis, Stephen W.; Hudson, Susan T.; Johnson, P. D.

    1992-06-01

    NASA's Marshall Space Flight Center has established a cold airflow turbine test program to experimentally determine the performance of liquid rocket engine turbopump drive turbines. Testing of the SSME alternate turbopump development (ATD) fuel turbine was conducted for back-to-back comparisons with the baseline SSME fuel turbine results obtained in the first quarter of 1991. Turbine performance, Reynolds number effects, and turbine diagnostics, such as stage reactions and exit swirl angles, were investigated at the turbine design point and at off-design conditions. The test data showed that the ATD fuel turbine test article was approximately 1.4 percent higher in efficiency and flowed 5.3 percent more than the baseline fuel turbine test article. This paper describes the method and results used to validate the ATD fuel turbine aerodynamic design. The results are being used to determine the ATD high pressure fuel turbopump (HPFTP) turbine performance over its operating range, anchor the SSME ATD steady-state performance model, and validate various prediction and design analyses.

  7. Cold flow testing of the Space Shuttle Main Engine alternate turbopump development high pressure fuel turbine model

    NASA Technical Reports Server (NTRS)

    Gaddis, Stephen W.; Hudson, Susan T.; Johnson, P. D.

    1992-01-01

    NASA's Marshall Space Flight Center has established a cold airflow turbine test program to experimentally determine the performance of liquid rocket engine turbopump drive turbines. Testing of the SSME alternate turbopump development (ATD) fuel turbine was conducted for back-to-back comparisons with the baseline SSME fuel turbine results obtained in the first quarter of 1991. Turbine performance, Reynolds number effects, and turbine diagnostics, such as stage reactions and exit swirl angles, were investigated at the turbine design point and at off-design conditions. The test data showed that the ATD fuel turbine test article was approximately 1.4 percent higher in efficiency and flowed 5.3 percent more than the baseline fuel turbine test article. This paper describes the method and results used to validate the ATD fuel turbine aerodynamic design. The results are being used to determine the ATD high pressure fuel turbopump (HPFTP) turbine performance over its operating range, anchor the SSME ATD steady-state performance model, and validate various prediction and design analyses.

  8. Identification of space shuttle main engine dynamics

    NASA Technical Reports Server (NTRS)

    Duyar, Ahmet; Guo, Ten-Huei; Merrill, Walter C.

    1989-01-01

    System identification techniques are used to represent the dynamic behavior of the Space Shuttle Main Engine. The transfer function matrices of the linearized models of both the closed loop and the open loop system are obtained by using the recursive maximum likelihood method.

  9. Design of a cold-flow test facility for the high pressure fuel turbopump turbine of the Space Shuttle main engine

    NASA Astrophysics Data System (ADS)

    Studevan, Colin C.

    1993-12-01

    The design and installation at the Naval Postgraduate School of a cold-flow test facility for the turbine of the high-pressure fuel turbopump of the Space Shuttle Main Engine, is reported. The specific article to be tested is the 'Alternate Development Model' designed and manufactured by Pratt & Whitney. The design of individual components is documented. The installation of the facility subsystem is described in detail. A preliminary estimation of turbine performance is made.

  10. Space shuttle main engine computed tomography applications

    NASA Technical Reports Server (NTRS)

    Sporny, Richard F.

    1990-01-01

    For the past two years the potential applications of computed tomography to the fabrication and overhaul of the Space Shuttle Main Engine were evaluated. Application tests were performed at various government and manufacturer facilities with equipment produced by four different manufacturers. The hardware scanned varied in size and complexity from a small temperature sensor and turbine blades to an assembled heat exchanger and main injector oxidizer inlet manifold. The evaluation of capabilities included the ability to identify and locate internal flaws, measure the depth of surface cracks, measure wall thickness, compare manifold design contours to actual part contours, perform automatic dimensional inspections, generate 3D computer models of actual parts, and image the relationship of the details in a complex assembly. The capabilities evaluated, with the exception of measuring the depth of surface flaws, demonstrated the existing and potential ability to perform many beneficial Space Shuttle Main Engine applications.

  11. General view of a Space Shuttle Main Engine (SSME) mounted ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of a Space Shuttle Main Engine (SSME) mounted on an SSME engine handler, taken in the SSME Processing Facility at Kennedy Space Center. The most prominent features of the engine assembly in this view are the Low-Pressure Fuel Turbopump Discharge Duct looping around the right side and underneath the assembly, the High-Pressure Fuel Turbopump located on the lower left portion of the assembly, the Engine Controller and Main Fuel Valve Hydraulic Actuator located on the upper portion of the assembly and the Low-Pressure Oxidizer Turbopump Discharge Duct at the top of the engine assembly in this view. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  12. Closeup side view of Space Shuttle Main Engine (SSME) 2059 ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Close-up side view of Space Shuttle Main Engine (SSME) 2059 mounted in a SSME Engine Handler near the Drying Area in the High Bay section of the SSME Processing Facility. The prominent features of the SSME in this view are the hot-gas expansion nozzle extending from the approximate image center toward the image right. The main-engine components extend from the approximate image center toward image right until it meets up with the mount for the SSME Engine Handler. The engine is rotated to a position where the major components in the view are the Low-Pressure Fuel Turbopump Discharge Duct with reflective foil insulation on the upper side of the engine, the Low-Pressure Oxidizer Turbopump and its Discharge Duct on the right side of the engine assembly extending itself down and wrapping under the bottom side of the assembly to the High-Pressure Oxidizer Turbopump pump. The High-Pressure Oxidizer Turbopump Discharge Duct exists the turbopump and extends up to the top side of the assembly where it enters the main oxidizer valve. The sphere on the lower side of the engine assembly is an accumulator that is part of the SSMEs POGO suppression system. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  13. Space shuttle main engine vibration data base

    NASA Technical Reports Server (NTRS)

    Lewallen, Pat

    1986-01-01

    The Space Shuttle Main Engine Vibration Data Base is described. Included is a detailed description of the data base components, the data acquisition process, the more sophisticated software routines, and the future data acquisition methods. Several figures and plots are provided to illustrate the various output formats accessible to the user. The numerous vibration data recall and analysis capabilities available through automated data base techniques are revealed.

  14. Space shuttle main engine plume radiation model

    NASA Technical Reports Server (NTRS)

    Reardon, J. E.; Lee, Y. C.

    1978-01-01

    The methods are described which are used in predicting the thermal radiation received by space shuttles, from the plumes of the main engines. Radiation to representative surface locations were predicted using the NASA gaseous plume radiation GASRAD program. The plume model is used with the radiative view factor (RAVFAC) program to predict sea level radiation at specified body points. The GASRAD program is described along with the predictions. The RAVFAC model is also discussed.

  15. General view of a Space Shuttle Main Engine (SSME) mounted ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of a Space Shuttle Main Engine (SSME) mounted on an SSME engine handler, taken in the SSME Processing Facility at Kennedy Space Center. The most prominent features of the engine assembly in this view are the Low-Pressure Oxidizer Turbopump Discharge Duct looping around the right side of the engine assembly then turning in and connecting to the High-Pressure Oxidizer Turbopump. The sphere in the approximate center of the assembly is the POGO System Accumulator, the Engine Controller is located on the bottom and slightly left of the center of the Engine Assembly in this view. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  16. The shuttle main engine: A first look

    NASA Technical Reports Server (NTRS)

    Schreur, Barbara

    1996-01-01

    Anyone entering the Space Shuttle Main Engine (SSME) team attends a two week course to become familiar with the design and workings of the engine. This course provides intensive coverage of the individual hardware items and their functions. Some individuals, particularly those involved with software maintenance and development, have felt overwhelmed by this volume of material and their lack of a logical framework in which to place it. To provide this logical framework, it was decided that a brief self-taught introduction to the overall operation of the SSME should be designed. To aid the people or new team members with an interest in the software, this new course should also explain the structure and functioning of the controller and its software. This paper presents a description of this presentation.

  17. Finite element analysis of the Space Shuttle Main Engine (SSME) alternate turbopump development (ATD) high pressure oxydizer turbopump (HPOTP)

    NASA Astrophysics Data System (ADS)

    Ham-Battista, G. L.; Helmick, G. L.; Hunt, G. L.; Franck, C. G.

    1993-04-01

    A 3D model of all stationary components of the ATD HPOTP is analyzed using a superelement solution technique to obtain a better understanding of the pump behavior and to support pump testing. Emphasis is place on the methods used for determining deflections. As part of the model verification, analyses were conducted on the main housing model under proof-pressure and push-test loading conditions. The analysis at 109 percent rate power level resulted in asymmetric deformation patterns which were used to calculate operating and rub clearances. The present analysis is considered to provide the most realistic representation of the ATD HPOTP to date.

  18. Space shuttle main engine hardware simulation

    NASA Technical Reports Server (NTRS)

    Vick, H. G.; Hampton, P. W.

    1985-01-01

    The Huntsville Simulation Laboratory (HSL) provides a simulation facility to test and verify the space shuttle main engine (SSME) avionics and software system using a maximum complement of flight type hardware. The HSL permits evaluations and analyses of the SSME avionics hardware, software, control system, and mathematical models. The laboratory has performed a wide spectrum of tests and verified operational procedures to ensure system component compatibility under all operating conditions. It is a test bed for integration of hardware/software/hydraulics. The HSL is and has been an invaluable tool in the design and development of the SSME.

  19. Studies and analyses of the space shuttle main engine: High-pressure oxidizer turbopump failure information propagation model

    NASA Technical Reports Server (NTRS)

    Glover, R. C.; Rudy, S. W.; Tischer, A. E.

    1987-01-01

    The high-pressure oxidizer turbopump (HPOTP) failure information propagation model (FIPM) is presented. The text includes a brief discussion of the FIPM methodology and the various elements which comprise a model. Specific details of the HPOTP FIPM are described. Listings of all the HPOTP data records are included as appendices.

  20. Analysis of experimental shaft seal data for high-performance turbomachines, as for Space Shuttle main engines

    NASA Technical Reports Server (NTRS)

    Hendricks, R. C.; Braun, M. J.; Mullen, R. L.; Burcham, R. E.; Diamond, W. A.

    1985-01-01

    High-pressure, high-temperature seal flow (leakage) data for nonrotating and rotating Raleigh-step and convergent-tapered-bore seals were characterized in terms of a normalized flow coefficient. The data for normalized Rayleigh-steip and nonrotating tapered-bore seals were in reasonable agreement with theory, but data for the rotating tapered-bore seals were not. The tapered-bore-seal operational clearances estimated from the flow data were significantly larger than calculated. Although clearances are influenced by wear from conical to cylindrical geometry and errors in clearance corrections, the problem was isolated to the shaft temperature - rotational speed clearance correction. The geometric changes support the use of some conical convergence in any seal. Under these conditions rotation reduced the normalized flow coefficiently by nearly 10 percent.

  1. Analysis of experimental shaft seal data for high-performance turbomachines - As for Space Shuttle main engines

    NASA Technical Reports Server (NTRS)

    Hendricks, R. C.; Mullen, R. L.; Braun, M. J.; Burcham, R. E.; Diamond, W. A.

    1987-01-01

    High-pressure, high-temperature seal flow (leakage) data for nonrotating and rotating Raleigh-step and convergent-tapered-bore seals were characterized in terms of a normalized flow coefficient. The data for normalized Rayleigh-step and nonrotating tapered-bore seals were in reasonable agreement with theory, but data for the rotating tapered-bore seals were not. The tapered-bore-seal operational clearances estimated from the flow data were significantly larger than calculated. Although clearances are influenced by wear from conical to cylindrical geometry and errors in clearance corrections, the problem was isolated to the shaft temperature - rotational speed clearance correction. The geometric changes support the use of some conical convergence in any seal. Under these conditions rotation reduced the normalized flow coefficiently by nearly 10 percent.

  2. Improvement of Space Shuttle Main Engine Low Frequency Acceleration Measurements

    NASA Technical Reports Server (NTRS)

    Stec, Robert C.

    1999-01-01

    The noise floor of low frequency acceleration data acquired on the Space Shuttle Main Engines is higher than desirable. Difficulties of acquiring high quality acceleration data on this engine are discussed. The approach presented in this paper for reducing the acceleration noise floor focuses on a search for an accelerometer more capable of measuring low frequency accelerations. An overview is given of the current measurement system used to acquire engine vibratory data. The severity of vibration, temperature, and moisture environments are considered. Vibratory measurements from both laboratory and rocket engine tests are presented.

  3. Space Shuttle Main Engine real time stability analysis

    NASA Astrophysics Data System (ADS)

    Kuo, F. Y.

    1993-06-01

    The Space Shuttle Main Engine (SSME) is a reusable, high performance, liquid rocket engine with variable thrust. The engine control system continuously monitors the engine parameters and issues propellant valve control signals in accordance with the thrust and mixture ratio commands. A real time engine simulation lab was installed at MSFC to verify flight software and to perform engine dynamic analysis. A real time engine model was developed on the AD100 computer system. This model provides sufficient fidelity on the dynamics of major engine components and yet simplified enough to be executed in real time. The hardware-in-the-loop type simulation and analysis becomes necessary as NASA is continuously improving the SSME technology, some with significant changes in the dynamics of the engine. The many issues of interfaces between new components and the engine can be better understood and be resolved prior to the firing of the engine. In this paper, the SSME real time simulation Lab at the MSFC, the SSME real time model, SSME engine and control system stability analysis, both in real time and non-real time is presented.

  4. General view of a Space Shuttle Main Engine (SSME) mounted ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of a Space Shuttle Main Engine (SSME) mounted on an SSME engine handler, taken in the SSME Processing Facility at Kennedy Space Center. The most prominent features of the engine assembly in this view are the Low-Pressure Fuel Turbopump Discharge Duct looping diagonally across the top of the assembly and connecting to the High-Pressure Fuel Turbopump, the Low-Pressure Oxidizer Turbopump (LPOTP) located center right of the assembly and the LPOTP Discharge Duct looping around from the pump to the underside of the engine assembly in this view. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  5. Closeup view of the top of Space Shuttle Main Engine ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Close-up view of the top of Space Shuttle Main Engine (SSME) 2057 mounted in a SSME Engine Handler in the Vertical Processing area of the SSME Processing Facility at Kennedy Space Center. The most prominent components in this view is the large Low-Pressure Oxidizer Turbopump (LPOTP) Discharge Duct wrapping itself around the right side of the engine assembly. The smaller tube to the left of LPOTP Discharge Duct is the High-Pressure Oxidizer Duct used to supply the turbine of the LPOTP. The other major feature in this view is the Low-Pressure Fuel Turbopump at the top of the engine assembly. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  6. SPACE SHUTTLE MAIN ENGINE NO. 2036, THE FIRST BLOCK I ENGINE TO FLY

    NASA Technical Reports Server (NTRS)

    1995-01-01

    Space Shuttle Main Engine (SSME) No. 2036, the first of the new Block I engines to fly, awaits installation into position one of the Orbiter Discovery in Orbiter Processing Facility 3 during preparation of the spaceplane for the STS-70 mission. The advanced powerplant features a new high- pressure liquid oxygen turbopump, a two-duct powerhead, a baffleless main injector, single-coil heat exchanger and start sequence modifications. These modifications are designed to improve both engine performance and safety.

  7. Space Shuttle Main Engine performance analysis

    NASA Astrophysics Data System (ADS)

    Santi, L. Michael

    1993-11-01

    For a number of years, NASA has relied primarily upon periodically updated versions of Rocketdyne's power balance model (PBM) to provide space shuttle main engine (SSME) steady-state performance prediction. A recent computational study indicated that PBM predictions do not satisfy fundamental energy conservation principles. More recently, SSME test results provided by the Technology Test Bed (TTB) program have indicated significant discrepancies between PBM flow and temperature predictions and TTB observations. Results of these investigations have diminished confidence in the predictions provided by PBM, and motivated the development of new computational tools for supporting SSME performance analysis. A multivariate least squares regression algorithm was developed and implemented during this effort in order to efficiently characterize TTB data. This procedure, called the 'gains model,' was used to approximate the variation of SSME performance parameters such as flow rate, pressure, temperature, speed, and assorted hardware characteristics in terms of six assumed independent influences. These six influences were engine power level, mixture ratio, fuel inlet pressure and temperature, and oxidizer inlet pressure and temperature. A BFGS optimization algorithm provided the base procedure for determining regression coefficients for both linear and full quadratic approximations of parameter variation. Statistical information relative to data deviation from regression derived relations was also computed. A new strategy for integrating test data with theoretical performance prediction was also investigated. The current integration procedure employed by PBM treats test data as pristine and adjusts hardware characteristics in a heuristic manner to achieve engine balance. Within PBM, this integration procedure is called 'data reduction.' By contrast, the new data integration procedure, termed 'reconciliation,' uses mathematical optimization techniques, and requires both

  8. Space Shuttle Main Engine performance analysis

    NASA Technical Reports Server (NTRS)

    Santi, L. Michael

    1993-01-01

    For a number of years, NASA has relied primarily upon periodically updated versions of Rocketdyne's power balance model (PBM) to provide space shuttle main engine (SSME) steady-state performance prediction. A recent computational study indicated that PBM predictions do not satisfy fundamental energy conservation principles. More recently, SSME test results provided by the Technology Test Bed (TTB) program have indicated significant discrepancies between PBM flow and temperature predictions and TTB observations. Results of these investigations have diminished confidence in the predictions provided by PBM, and motivated the development of new computational tools for supporting SSME performance analysis. A multivariate least squares regression algorithm was developed and implemented during this effort in order to efficiently characterize TTB data. This procedure, called the 'gains model,' was used to approximate the variation of SSME performance parameters such as flow rate, pressure, temperature, speed, and assorted hardware characteristics in terms of six assumed independent influences. These six influences were engine power level, mixture ratio, fuel inlet pressure and temperature, and oxidizer inlet pressure and temperature. A BFGS optimization algorithm provided the base procedure for determining regression coefficients for both linear and full quadratic approximations of parameter variation. Statistical information relative to data deviation from regression derived relations was also computed. A new strategy for integrating test data with theoretical performance prediction was also investigated. The current integration procedure employed by PBM treats test data as pristine and adjusts hardware characteristics in a heuristic manner to achieve engine balance. Within PBM, this integration procedure is called 'data reduction.' By contrast, the new data integration procedure, termed 'reconciliation,' uses mathematical optimization techniques, and requires both

  9. Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 2: High pressure oxidizer turbo-pump turbine end bearing analysis

    NASA Technical Reports Server (NTRS)

    Sisk, Gregory A.

    1989-01-01

    The high-pressure oxidizer turbopump (HPOTP) consists of two centrifugal pumps, on a common shaft, that are directly driven by a hot-gas turbine. Pump shaft axial thrust is balanced in that the double-entry main inducer/impeller is inherently balanced and the thrusts of the preburner pump and turbine are nearly equal but opposite. Residual shaft thrust is controlled by a self-compensating, non-rubbing, balance piston. Shaft hang-up must be avoided if the balance piston is to perform properly. One potential cause of shaft hang-up is contact between the Phase 2 bearing support and axial spring cartridge of the HPOTP main pump housing. The status of the bearing support/axial spring cartridge interface is investigated under current loading conditions. An ANSYS version 4.3, three-dimensional, finite element model was generated on Lockheed's VAX 11/785 computer. A nonlinear thermal analysis was then executed on the Marshall Space Flight Center Engineering Analysis Data System (EADS). These thermal results were then applied along with the interference fit and bolt preloads to the model as load conditions for a static analysis to determine the gap status of the bearing support/axial spring cartridge interface. For possible further analysis of the local regions of HPOTP main pump housing assembly, detailed ANSYS submodels were generated using I-DEAS Geomod and Supertab (Appendix A).

  10. A study of boiling heat transfer as applied to the cooling of ball bearings in the high pressure oxygen turbopump of the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Schreiber, Will

    1986-01-01

    Two sets of ball bearings support the main shaft within the High Pressure Oxygen Turbopump (HPOTP) in the Space Shuttle Main Engine (SSME). In operation, these bearings are cooled and lubricated with high pressure liquid oxygen (LOX) flowing axially through the bearing assembly. Currently, modifications in the assembly design are being contemplated in order to enhance the lifetime of the bearings and to allow the HPOTP to operate under larger loads. An understanding of the fluid dynamics and heat transfer characteristics of the flowing LOX is necessary for the implementation of these design changes. The proposed computational model of the LOX fluid dynamics, in addition to dealing with a turbulent flow in a complex geometry, must address the complication associated with boiling and two-phase flow. The feasibility of and possible methods for modeling boiling heat transfer are considered. The theory of boiling as pertains to this particular problem is reviewed. Recommendations are given for experiments which would be necessary to establish validity for correlations needed to model boiling.

  11. Fault diagnosis for the Space Shuttle main engine

    NASA Technical Reports Server (NTRS)

    Duyar, Ahmet; Merrill, Walter

    1992-01-01

    A conceptual design of a model-based fault detection and diagnosis system is developed for the Space Shuttle main engine. The design approach consists of process modeling, residual generation, and fault detection and diagnosis. The engine is modeled using a discrete time, quasilinear state-space representation. Model parameters are determined by identification. Residuals generated from the model are used by a neural network to detect and diagnose engine component faults. Fault diagnosis is accomplished by training the neural network to recognize the pattern of the respective fault signatures. Preliminary results for a failed valve, generated using a full, nonlinear simulation of the engine, are presented. These results indicate that the developed approach can be used for fault detection and diagnosis. The results also show that the developed model is an accurate and reliable predictor of the highly nonlinear and very complex engine.

  12. The simulation of the alternate turbopump development high pressure oxygen and fuel turbopumps for the space shuttle main engine using the Shaberth computer program

    NASA Technical Reports Server (NTRS)

    Mcdonald, Gary H.

    1988-01-01

    The Space Shuttle Main Engine (SSME) is basically comprised of a combustion chamber and nozzle, high and low pressure oxygen turbopumps and high and low pressure fuel turbopumps. In the current configuration, the high pressure fuel (HPTFP) and high pressure oxygen turbopumps (HPOTP) have experienced a history of ball bearing wear. The wear problem can be attributed to numerous factors including the hydrodynamic axial and radial loads caused by the flow of liquid oxygen and liquid hydrogen through the turbopump impellers and turbine. Also, friction effects between the rolling elements, races, and cage can create thermally induced bearing geometry changes. To alleviate some of the current configuration problems, an alternate turbopump development (ATD) was proposed. However, the ATD HPOTP and HPTFP are constrained to operate interchangeably with the current turbopumps, thus, the operation conditions must be similar. The ATD configuration features a major change in bearings used to support the integrated shaft, impeller, and turbine system. A single ball and single roller will replace the pump-end and turbine and duplex ball bearings. The Shaft-Bearing-Thermal (SHABERTH) computer code was used to model the ATD HPOTP and ATD HPFTP configurations. A two bearing model was used to simulate the HPOTP and HPFTP bearings and shaft geometry. From SHABERTH, a comparison of bearing reaction loads, frictional heat generation rates, and Hertz contact stresses will be attempted with analysis at the 109 percent and 65 percent power levels.

  13. Developmental problems and their solution for the Space Shuttle main engine alternate liquid oxygen high-pressure turbopump: Anomaly or failure investigation the key

    NASA Astrophysics Data System (ADS)

    Ryan, R.; Gross, L. A.

    1995-05-01

    The Space Shuttle main engine (SSME) alternate high-pressure liquid oxygen pump experienced synchronous vibration and ball bearing life problems that were program threatening. The success of the program hinged on the ability to solve these development problems. The design and solutions to these problems are engirded in the lessons learned and experiences from prior programs, technology programs, and the ability to properly conduct failure or anomaly investigations. The failure investigation determines the problem cause and is the basis for recommending design solutions. For a complex problem, a comprehensive solution requires that formal investigation procedures be used, including fault trees, resolution logic, and action items worked through a concurrent engineering-multidiscipline team. The normal tendency to use an intuitive, cut-and-try approach will usually prove to be costly, both in money and time and will reach a less than optimum, poorly understood answer. The SSME alternate high-pressure oxidizer turbopump development has had two complex problems critical to program success: (1) high synchronous vibrations and (2) excessive ball bearing wear. This paper will use these two problems as examples of this formal failure investigation approach. The results of the team's investigation provides insight into the complexity of the turbomachinery technical discipline interacting/sensitivities and the fine balance of competing investigations required to solve problems and guarantee program success. It is very important to the solution process that maximum use be made of the resources that both the contractor and Government can bring to the problem in a supporting and noncompeting way. There is no place for the not-invented-here attitude. The resources include, but are not limited to: (1) specially skilled professionals; (2) supporting technologies; (3) computational codes and capabilities; and (4) test and manufacturing facilities.

  14. Developmental problems and their solution for the Space Shuttle main engine alternate liquid oxygen high-pressure turbopump: Anomaly or failure investigation the key

    NASA Technical Reports Server (NTRS)

    Ryan, R.; Gross, L. A.

    1995-01-01

    The Space Shuttle main engine (SSME) alternate high-pressure liquid oxygen pump experienced synchronous vibration and ball bearing life problems that were program threatening. The success of the program hinged on the ability to solve these development problems. The design and solutions to these problems are engirded in the lessons learned and experiences from prior programs, technology programs, and the ability to properly conduct failure or anomaly investigations. The failure investigation determines the problem cause and is the basis for recommending design solutions. For a complex problem, a comprehensive solution requires that formal investigation procedures be used, including fault trees, resolution logic, and action items worked through a concurrent engineering-multidiscipline team. The normal tendency to use an intuitive, cut-and-try approach will usually prove to be costly, both in money and time and will reach a less than optimum, poorly understood answer. The SSME alternate high-pressure oxidizer turbopump development has had two complex problems critical to program success: (1) high synchronous vibrations and (2) excessive ball bearing wear. This paper will use these two problems as examples of this formal failure investigation approach. The results of the team's investigation provides insight into the complexity of the turbomachinery technical discipline interacting/sensitivities and the fine balance of competing investigations required to solve problems and guarantee program success. It is very important to the solution process that maximum use be made of the resources that both the contractor and Government can bring to the problem in a supporting and noncompeting way. There is no place for the not-invented-here attitude. The resources include, but are not limited to: (1) specially skilled professionals; (2) supporting technologies; (3) computational codes and capabilities; and (4) test and manufacturing facilities.

  15. Space Shuttle Main Engine Liquid Air Insulation Redesign Lessons Learned

    NASA Technical Reports Server (NTRS)

    Gaddy, Darrell; Carroll, Paul; Head, Kenneth; Fasheh, John; Stuart, Jessica

    2010-01-01

    The Space Shuttle Main Engine Liquid Air Insulation redesign was required to prevent the reoccurance of the STS-111 High Pressure Speed Sensor In-Flight Anomaly. The STS-111 In-Flight Anomaly Failure Investigation Team's initial redesign of the High Pressure Fuel Turbopump Pump End Ball Bearing Liquid Air Insulation failed the certification test by producing Liquid Air. The certification test failure indicated not only the High Pressure Fuel Turbopump Liquid Air Insulation, but all other Space Shuttle Main Engine Liquid Air Insulation. This paper will document the original Space Shuttle Main Engine Liquid Air STS-111 In-Flight Anomaly investigation, the heritage Space Shuttle Main Engine Insulation certification testing faults, the techniques and instrumentation used to accurately test the Liquid Air Insulation systems on the Stennis Space Center SSME test stand, the analysis techniques used to identify the Liquid Air Insulation problem areas and the analytical verification of the redesign before entering certification testing, Trade study down selected to three potential design solutions, the results of the development testing which down selected the final Liquid Air Redesign are also documented within this paper.

  16. Fatigue Failure of Space Shuttle Main Engine Turbine Blades

    NASA Technical Reports Server (NTRS)

    Swanson, Gregrory R.; Arakere, Nagaraj K.

    2000-01-01

    Experimental validation of finite element modeling of single crystal turbine blades is presented. Experimental results from uniaxial high cycle fatigue (HCF) test specimens and full scale Space Shuttle Main Engine test firings with the High Pressure Fuel Turbopump Alternate Turbopump (HPFTP/AT) provide the data used for the validation. The conclusions show the significant contribution of the crystal orientation within the blade on the resulting life of the component, that the analysis can predict this variation, and that experimental testing demonstrates it.

  17. Engine systems analysis results of the Space Shuttle Main Engine redesigned powerhead initial engine level testing

    NASA Astrophysics Data System (ADS)

    Sander, Erik J.; Gosdin, Dennis R.

    1992-07-01

    Engineers regularly analyze SSME ground test and flight data with respect to engine systems performance. Recently, a redesigned SSME powerhead was introduced to engine-level testing in part to increase engine operational margins through optimization of the engine internal environment. This paper presents an overview of the MSFC personnel engine systems analysis results and conclusions reached from initial engine level testing of the redesigned powerhead, and further redesigns incorporated to eliminate accelerated main injector baffle and main combustion chamber hot gas wall degradation. The conclusions are drawn from instrumented engine ground test data and hardware integrity analysis reports and address initial engine test results with respect to the apparent design change effects on engine system and component operation.

  18. General view of the Space Shuttle Main Engine (SSME) assembly ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of the Space Shuttle Main Engine (SSME) assembly with the expansion nozzle removed and resting on a cushioned mat on the floor of the SSME Processing Facility. The most prominent features in this view are the Low-pressure oxidizer Turbopump discharge Duct looping from the upper left side of the engine assembly to the lower left side of the assembly, the Low-Pressure Fuel Turbopump (LPFTP) is on the upper left of the assembly in this view and the LPFTP Discharge Duct loops from the upper left to upper right then turns back and down the assembly to the High-Pressure Fuel Turbopump on the lower right of the assembly. The Engine Controller and the Main fuel Valve Hydraulic Actuator are on the lower left portion of the assembly. The vertical rod that is in the approximate center of the engine assembly is a piece of ground support equipment call a Gimbal Actuator Replacement Strut which are used on the SSMEs when they are not installed in an orbiter. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  19. Model Verification and Validation Concepts for a Probabilistic Fracture Assessment Model to Predict Cracking of Knife Edge Seals in the Space Shuttle Main Engine High Pressure Oxidizer

    NASA Technical Reports Server (NTRS)

    Pai, Shantaram S.; Riha, David S.

    2013-01-01

    Physics-based models are routinely used to predict the performance of engineered systems to make decisions such as when to retire system components, how to extend the life of an aging system, or if a new design will be safe or available. Model verification and validation (V&V) is a process to establish credibility in model predictions. Ideally, carefully controlled validation experiments will be designed and performed to validate models or submodels. In reality, time and cost constraints limit experiments and even model development. This paper describes elements of model V&V during the development and application of a probabilistic fracture assessment model to predict cracking in space shuttle main engine high-pressure oxidizer turbopump knife-edge seals. The objective of this effort was to assess the probability of initiating and growing a crack to a specified failure length in specific flight units for different usage and inspection scenarios. The probabilistic fracture assessment model developed in this investigation combined a series of submodels describing the usage, temperature history, flutter tendencies, tooth stresses and numbers of cycles, fatigue cracking, nondestructive inspection, and finally the probability of failure. The analysis accounted for unit-to-unit variations in temperature, flutter limit state, flutter stress magnitude, and fatigue life properties. The investigation focused on the calculation of relative risk rather than absolute risk between the usage scenarios. Verification predictions were first performed for three units with known usage and cracking histories to establish credibility in the model predictions. Then, numerous predictions were performed for an assortment of operating units that had flown recently or that were projected for future flights. Calculations were performed using two NASA-developed software tools: NESSUS(Registered Trademark) for the probabilistic analysis, and NASGRO(Registered Trademark) for the fracture

  20. Space Shuttle Main Engine - The Relentless Pursuit of Improvement

    NASA Technical Reports Server (NTRS)

    VanHooser, Katherine P.; Bradley, Douglas P.

    2011-01-01

    The Space Shuttle Main Engine (SSME) is the only reusable large liquid rocket engine ever developed. The specific impulse delivered by the staged combustion cycle, substantially higher than previous rocket engines, minimized volume and weight for the integrated vehicle. The dual pre-burner configuration permitted precise mixture ratio and thrust control while the fully redundant controller and avionics provided a very high degree of system reliability and health diagnosis. The main engine controller design was the first rocket engine application to incorporate digital processing. The engine was required to operate at a high chamber pressure to minimize engine volume and weight. Power level throttling was required to minimize structural loads on the vehicle early in flight and acceleration levels on the crew late in ascent. Fatigue capability, strength, ease of assembly and disassembly, inspectability, and materials compatibility were all major considerations in achieving a fully reusable design. During the multi-decade program the design evolved substantially using a series of block upgrades. A number of materials and manufacturing challenges were encountered throughout SSME s history. Significant development was required for the final configuration of the high pressure turbopumps. Fracture control was implemented to assess life limits of critical materials and components. Survival in the hydrogen environment required assessment of hydrogen embrittlement. Instrumentation systems were a challenge due to the harsh thermal and dynamic environments within the engine. Extensive inspection procedures were developed to assess the engine components between flights. The Space Shuttle Main Engine achieved a remarkable flight performance record. All flights were successful with only one mission requiring an ascent abort condition, which still resulted in an acceptable orbit and mission. This was achieved in large part via extensive ground testing to fully characterize

  1. Space Shuttle Main Engine turbopump bearing assessment program

    NASA Technical Reports Server (NTRS)

    Breithaupt, Barbara Spiegel

    1994-01-01

    This paper documents the work done on the bearing assessment program over the past two and a half years. The objective of the program is to develop a nondestructive evaluation system for the space shuttle main engine high pressure oxidizer turbopumps which would be used to detect anomalies in installed bearings without component disassembly. Databases of various signatures are obtained by slowly turning the pump shafts before and after an engine firing. These signatures are then analyzed and compared to the original signatures to more accurately predict bearing wear.

  2. Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 7: High pressure fuel turbo-pump third stage impeller analysis

    NASA Technical Reports Server (NTRS)

    Pool, Kirby V.

    1989-01-01

    This volume summarizes the analysis used to assess the structural life of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbo-Pump (HPFTP) Third Stage Impeller. This analysis was performed in three phases, all using the DIAL finite element code. The first phase was a static stress analysis to determine the mean (non-varying) stress and static margin of safety for the part. The loads involved were steady state pressure and centrifugal force due to spinning. The second phase of the analysis was a modal survey to determine the vibrational modes and natural frequencies of the impeller. The third phase was a dynamic response analysis to determine the alternating component of the stress due to time varying pressure impulses at the outlet (diffuser) side of the impeller. The results of the three phases of the analysis show that the Third Stage Impeller operates very near the upper limits of its capability at full power level (FPL) loading. The static loading alone creates stresses in some areas of the shroud which exceed the yield point of the material. Additional cyclic loading due to the dynamic force could lead to a significant reduction in the life of this part. The cyclic stresses determined in the dynamic response phase of this study are based on an assumption regarding the magnitude of the forcing function.

  3. Thermographic Leak Detection of the Space Shuttle Main Engine Nozzle

    NASA Technical Reports Server (NTRS)

    Walker, James L.; Russell, Samuel S.

    1999-01-01

    The Space Shuttle Main Engines Nozzles consist of over one thousand tapered Inconel coolant tubes brazed to a stainless steel structural jacket. Liquid Hydrogen flows through the tubing, from the aft to forward end of the nozzle, under high pressure to maintain a thermal balance between the rocket exhaust and the nozzle wall. Three potential problems occur within the SSME nozzle coolant tubes as a result of manufacturing anomalies and the highly volatile service environment including poor or incomplete bonding of the tubes to the structural jacket, cold wall leaks and hot wall leaks. Of these conditions the identification of cold wall leaks has been the most problematic. The methods and results presented in this summary addresses the thermographic identification of cold wall "interstitial" leaks between the structural jacket and coolant tubes of the Space Shuttle Main Engines Nozzles.

  4. 28. Main engine air pump located to port side of ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    28. Main engine air pump located to port side of main engine cylinder beside engine bed. Dynamo lies aft of air pump (at right), pipe at extreme left of image carries lake water to condenser valves. - Ferry TICONDEROGA, Route 7, Shelburne, Chittenden County, VT

  5. Advanced Health Management System for the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Davidson, Matt; Stephens, John; Rodela, Chris

    2006-01-01

    Pratt & Whitney Rocketdyne, Inc., in cooperation with NASA-Marshall Space Flight Center (MSFC), has developed a new Advanced Health Management System (AHMS) controller for the Space Shuttle Main Engine (SSME) that will increase the probability of successfully placing the shuttle into the intended orbit and increase the safety of the Space Transportation System (STS) launches. The AHMS is an upgrade o the current Block II engine controller whose primary component is an improved vibration monitoring system called the Real-Time Vibration Monitoring System (RTVMS) that can effectively and reliably monitor the state of the high pressure turbomachinery and provide engine protection through a new synchronous vibration redline which enables engine shutdown if the vibration exceeds predetermined thresholds. The introduction of this system required improvements and modification to the Block II controller such as redesigning the Digital Computer Unit (DCU) memory and the Flight Accelerometer Safety Cut-Off System (FASCOS) circuitry, eliminating the existing memory retention batteries, installation of the Digital Signal Processor (DSP) technology, and installation of a High Speed Serial Interface (HSSI) with accompanying outside world connectors. Test stand hot-fire testing along with lab testing have verified successful implementation and is expected to reduce the probability of catastrophic engine failures during the shuttle ascent phase and improve safely by about 23% according to the Quantitative Risk Assessment System (QRAS), leading to a safer and more reliable SSME.

  6. Unique material requirements in the Space Shuttle Main Engines

    NASA Technical Reports Server (NTRS)

    Fulton, D. L.; Shoemaker, M. C.; Bashir, S.

    1983-01-01

    Components operating in staged-combustion cycle liquid fuel rocket engines such as the Space Shuttle Main Engines (SSMEs) are subjected to severe temperature changes during start/stop transients, together with extremely high pressures, corrosive gases, high fluid velocities, demanding weight-control criteria, etc. Attention is given to the selection and application of metallic and nonmetallic materials for high temperature resistance, cryogenic properties, and hydrogen and oxygen compatibility. The materials in question include polyimides, Kel-F, Armalon, and Teflon among plastics, and gold and copper platings, weld-overlays and heat treatment modifications among metals and metallic processing techniques. The polymeric materials are oxygen-resistant, and the metallic ones hydrogen-resistant.

  7. Analysis of thermoelastohydrodynamic performance of journal misaligned engine main bearings

    NASA Astrophysics Data System (ADS)

    Bi, Fengrong; Shao, Kang; Liu, Changwen; Wang, Xia; Zhang, Jian

    2015-05-01

    To understand the engine main bearings' working condition is important in order to improve the performance of engine. However, thermal effects and thermal effect deformations of engine main bearings are rarely considered simultaneously in most studies. A typical finite element model is selected and the effect of thermoelastohydrodynamic(TEHD) reaction on engine main bearings is investigated. The calculated method of main bearing's thermal hydrodynamic reaction and journal misalignment effect is finite difference method, and its deformation reaction is calculated by using finite element method. The oil film pressure is solved numerically with Reynolds boundary conditions when various bearing characteristics are calculated. The whole model considers a temperature-pressure-viscosity relationship for the lubricant, surface roughness effect, and also an angular misalignment between the journal and the bearing. Numerical simulations of operation of a typical I6 diesel engine main bearing is conducted and importance of several contributing factors in mixed lubrication is discussed. The performance characteristics of journal misaligned main bearings under elastohydrodynamic(EHD) and TEHD loads of an I6 diesel engine are received, and then the journal center orbit movement, minimum oil film thickness and maximum oil film pressure of main bearings are estimated over a wide range of engine operation. The model is verified through the comparison with other present models. The TEHD performance of engine main bearings with various effects under the influences of journal misalignment is revealed, this is helpful to understand EHD and TEHD effect of misaligned engine main bearings.

  8. General view of the Space Shuttle Main Engine (SSME) assembly ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of the Space Shuttle Main Engine (SSME) assembly with the expansion nozzle removed and resting on a cushioned mat on the floor of the SSME Processing Facility. The most prominent features in this view are the Low-pressure Fuel Turbopump discharge Duct looping from the upper left side of the engine assembly to the lower left side of the assembly, the Low-Pressure Oxidizer Turbopump (LPOTP) is on the upper left of the assembly in this view and the LPOTP Discharge Duct loops from the upper left to upper right. The sphere in the middle right side of the assembly in this view is the POGO System Accumulator , the partial sphere to its left and slightly more toward the center of the assembly is the Heat Exchanger on the Oxidizer Preburner side of the Hot Gas Manifold, beneath that is the High-Pressure Oxidizer Turbopump (HPOTP) and the HPOTP Discharge duct loops from the pump around to the lower left of the assembly. The Pneumatic Control Assembly is in the approximate center of the engine assembly in this view. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  9. The cost of performance - A comparison of the space transportation main engine and the Space Shuttle main engine

    NASA Technical Reports Server (NTRS)

    Barisa, B. B.; Flinchbaugh, G. D.; Zachary, A. T.

    1989-01-01

    This paper compares the cost of the Space Shuttle Main Engine (SSME) and the Space Transportation Main Engine (STME) proposed by the Advanced Launch System Program. A brief description of the SSME and STME engines is presented, followed by a comparison of these engines that illustrates the impact of focusing on acceptable performance at minimum cost (as for the STME) or on maximum performance (as for the SSME). Several examples of cost reduction methods are presented.

  10. Lubrication of Space Shuttle Main Engine Turbopump Bearings

    NASA Technical Reports Server (NTRS)

    Gibson, Howard; Munafo, Paul (Technical Monitor)

    2001-01-01

    The Space Shuttle has three main engines that are used for propulsion into orbit. These engines are fed propellants by four turbopumps on each engine. A main element in the turbopump is the bearings supporting the rotor that spins the turbine blades and the pump impeller. These bearings are required to spin at very high speeds, support radial and thrust loads, and have high wear resistance without the benefit of lubrication. The liquid hydrogen and oxygen propellants flow through the bearings to cool the surfaces. The volatile nature of the propellants excludes any conventional means of lubrication. Lubrication for these bearings is provided by the ball separator inside the bearing. The separator is a composite material that supplies a transfer film of lubrication to the rings and balls. New separator materials and lubrication schemes have been investigated at Marshall Space Flight Center in a bearing test rig with promising results. Hybrid bearings with silicon nitride balls have also been evaluated. The use of hybrid, silicon nitride ball bearings in conjunction -with better separator materials has shown excellent results. The work that Marshall has done is being utilized in turbopumps flying on the space shuttle fleet and will be utilized in future space travel. This result of this work is valuable for all aerospace and commercial applications where high-speed bearings are used.

  11. Space Shuttle Main Engine (SSME) Reliability and Analysis Evolution

    NASA Technical Reports Server (NTRS)

    Stephens, Walter E.; Rogers, James H.; Biggs, Robert E.

    2010-01-01

    The Space Shuttle Main Engine (SSME) is a large thrust class, reusable, staged combustion cycle rocket engine employing liquid hydrogen and liquid oxygen propellants. A cluster of three SSMEs is used on every space shuttle mission to propel the space shuttle orbiter vehicle into low earth orbit. Development of the SSME began in the early 70 s and the first flight of the space shuttle occurred in 1981. Today, the SSME has accrued over one million seconds of ground test and flight operational time, launching 129 space shuttle missions. Given that the SSME is used to launch a manned vehicle, its reliability must be commensurate for the task. At the same time, the SSME is a high performance, high power density engine which traditionally does not lend itself towards high reliability. Furthermore, throughout its history, the SSME operational envelope has been explored and expanded leading to several major test failures. Hence, assessing the reliability of the SSME throughout its history has been a challenging undertaking. This paper provides a review and discussion of SSME reliability assessment techniques and results over its history. Basic reliability drivers such as engine design, test program, major failures, redesigns and upgrades will also be discussed.

  12. Finite element models of the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Muller, G. R.

    1980-01-01

    Finite element models were developed as input to dynamic simulations of the high pressure fuel turbopump (HPFTP), the high pressure oxidizer turbopump (HPOTP), and the space shuttle main engine (SSME). Descriptions are provided for the five basic finite element models: HPFTP rotor, HPFTP case, HPOTP rotor, HPOTP case, and SSME (excluding turbopumps). Modal results are presented for the HPFTP rotor, HPFTP case, HPOTP rotor, coupled HPFTP rotor and case, HPOTP case, coupled HPOTP rotor and case, SSME (excluding turbopumps), and SSME (including turbopumps). Results for the SSME (including turbopumps) model are compared to data from a SSME HPOTP modal survey.

  13. Main Chamber Injectors for Advanced Hydrocarbon Booster Engines

    NASA Technical Reports Server (NTRS)

    Long, Matthew R.; Bazarov, Vladimir G.; Anderson, William E.

    2003-01-01

    Achieving the highest possible specific impulse has long been a key driver for space launch systems. Recently, more importance has been placed on the need for increased reliability and streamlined launch operations. These general factors along with more specific mission requirements have provided a new focus that is centered on the oxidizer rich staged combustion (ORSC) cycle. Despite a history of use in Russia that extends back to the 1960's, a proven design methodology for ORSC cycle engines does not exist in the West. This lack of design expertise extends to the main chamber injector, a critical subcomponent that largely determines the engine performance and main chamber life. The goals of the effort described here are to establish an empirical knowledge base to provide a fundamental understanding of main chamber injectors and for verification of an injector design methodology for the ORSC cycle. The design of a baseline injector element, derived from information on Russian engines in the open literature, is presented. The baseline injector comprises a gaseous oxidizer core flow and an annular swirling fuel flow. Sets of equations describing the steady-state and the dynamic characteristics of the injector are presented; these equations, which form the basis of the design analysis methodology, will be verified in tests later this year. On-going cold flow studies, using nitrogen and water as simulants, are described which indicate highly atomized and symmetric sprays.

  14. Predicting engine parameters using the optic spectrum of the space shuttle main engine exhaust plume

    NASA Astrophysics Data System (ADS)

    Srivastava, Ashok N.; Buntine, Wray

    The Optical Plume Anomaly Detection (OPAD) system is under development to predict engine anomalies and engine parameters of the Space Shuttle's Main Engine (SSME). The anomaly detection is based on abnormal metal concentrations in the optical spectrum of the rocket plume. Such abnormalities could be indicative of engine corrosion or other malfunctions. Here, we focus on the second task of the OPAD system, namely the prediction of engine parameters such as rated power level (RPL) and mixture ratio (MR). Because of the high dimensionality of the spectrum, we developed a linear algorithm to resolve the optical spectrum of the exhaust plume into a number of separate components, each with a different physical interpretation. These components are used to predict the metal concentrations and engine parameters for online support of ground-level testing of the SSME. Currently, these predictions are labor intensive and cannot be done online. We predict RPL using neural networks and give preliminary results.

  15. Space shuttle three main engine return to launch site abort

    NASA Technical Reports Server (NTRS)

    Carter, J. F.; Bown, R. L.

    1975-01-01

    A Return-to-Launch-Site (RTLS) abort with three Space Shuttle Main Engines (SSME) operational was examined. The results are trajectories and main engine cutoff conditions that are approximately the same as for a two SSME case. Requiring the three SSME solution to match the two SSME abort eliminates additional crew training and is accomplished with negligible software impact.

  16. The space transportation main engine phase A' study

    NASA Technical Reports Server (NTRS)

    1987-01-01

    The Space Transportation Main Engine Phase A prime study was conducted over a 7 month period as an extension to the Phase A study. The Phase A prime program was designed to expand the study effort completed in Phase A, focusing on the baseline engine configuration selected. Analysis and trade studies were conducted to further optimize some of the major engine subsystems. These changes resulted in improvements to the baseline engine. Several options were evaluated for consideration by vehicle contractors.

  17. Space Shuttle Main Engine (SSME) alternate turbopump design and development

    NASA Astrophysics Data System (ADS)

    Mitchell, J. P.; Price, J. L.

    1992-08-01

    The development of high-pressure turbopumps for the 400,000-lb-thrust class Space Shuttle Main Engine (SSME) is examined with attention given to reducing maintenance and improving turbopump life. The high-pressure turbopump is designed with single-crystal turbine blades, an integral disk/shaft, a stiff rotor with larger bearings, and advanced homogeneous structural housings. The High-pressure Fuel Turbopump is shown to raise the fuel pressure significantly to enhance injection at all thrust levels, and the High-pressure Oxidizer Turbopump enhances oxidizer pressure for adequate injection at all power levels. Both of the turbopumps are tested in a high-pressure facility with attention given to start and shutdown characteristics, and breakaway torque and inertias are shown to influence combustor priming, ignition, temperature spikes, and thrust.

  18. LOX/Methane Main Engine Igniter Tests and Modeling

    NASA Technical Reports Server (NTRS)

    Breisacher, Kevin J.; Ajmani, Kumund

    2008-01-01

    The LOX/methane propellant combination is being considered for the Lunar Surface Access Module ascent main engine propulsion system. The proposed switch from the hypergolic propellants used in the Apollo lunar ascent engine to LOX/methane propellants requires the development of igniters capable of highly reliable performance in a lunar surface environment. An ignition test program was conducted that used an in-house designed LOX/methane spark torch igniter. The testing occurred in Cell 21 of the Research Combustion Laboratory to utilize its altitude capability to simulate a space vacuum environment. Approximately 750 ignition test were performed to evaluate the effects of methane purity, igniter body temperature, spark energy level and frequency, mixture ratio, flowrate, and igniter geometry on the ability to obtain successful ignitions. Ignitions were obtained down to an igniter body temperature of approximately 260 R with a 10 torr back-pressure. The data obtained is also being used to anchor a CFD based igniter model.

  19. Duct flow nonuniformities study for space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Thoenes, J.

    1985-01-01

    To improve the Space Shuttle Main Engine (SSME) design and for future use in the development of generation rocket engines, a combined experimental/analytical study was undertaken with the goals of first, establishing an experimental data base for the flow conditions in the SSME high pressure fuel turbopump (HPFTP) hot gas manifold (HGM) and, second, setting up a computer model of the SSME HGM flow field. Using the test data to verify the computer model it should be possible in the future to computationally scan contemplated advanced design configurations and limit costly testing to the most promising design. The effort of establishing and using the computer model is detailed. The comparison of computational results and experimental data observed clearly demonstrate that computational fluid mechanics (CFD) techniques can be used successfully to predict the gross features of three dimensional fluid flow through configurations as intricate as the SSME turbopump hot gas manifold.

  20. Stability testing of a modified Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Dennis, H.; Hutt, J.; Nesman, T.

    1991-01-01

    The testing of the combustion stability characteristics of Space Shuttle Main Engine (SSME) 0208 is described in terms of augmenting the technology base for large O/H thrust-chamber assemblies. The throat area is increased by 12 percent over that of the flight SSMEs, and the thrust chamber assembly does not include stability aids. Acoustic modes in the chamber are excited by means of rapid pressure generators employed in the start-transient through mainstage operations. Stability characteristics are determined by damp times which are facilitated by high-frequency instrumentation measuring oscillations and locating stable operating regions. All vibration modes are damped to within the requirements for a chamber mode set forth by the Chemical Propulsion Information Agency. No sustained chamber acoustic oscillations are exhibited in engine 0208's combustion chamber configuration in spite of the absence of baffles and acoustic cavities.

  1. Testing certifies the Space Shuttle Main Engine life improvement modifications

    NASA Technical Reports Server (NTRS)

    Wood, Byron K.

    1986-01-01

    Development and certification tests have been conducted on the Space Shuttle Main Engine to verify design changes made on the high-pressure turbopumps to expand operating margin at full-power level, increase life, and reduce maintenance requirements. Design changes are summarized and the verification process is described in detail. Methods of testing turbopumps for increased rotor stability, reduced bearing loads, extended bearing and turbine blade life, and reduced turbine operating temperatures are also described. Accomplishments to date in extending both the power level and life of the SSME are summarized.

  2. Jet Boost Pumps For The Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Meng, Sen Y.

    1991-01-01

    Brief report proposes use of jet boost pumps in conjunction with main pumps supplying liquid hydrogen and liquid oxygen to main engine of Space Shuttle. Main part of pump has no moving parts. Benefits include increased reliability, simplified ducts, and decreased weight.

  3. Closeup view of a Space Shuttle Main Engine (SSME) installed ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Close-up view of a Space Shuttle Main Engine (SSME) installed in position number one on the Orbiter Discovery. A ground-support mobile platform is in place below the engine to assist in technicians with the installation of the engine. This Photograph was taken in the Orbiter Processing Facility at the Kennedy Space Center. - Space Transportation System, Orbiter Discovery (OV-103), Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  4. General view of Main Steam Engine for shop lineshaft, cylinder ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of Main Steam Engine for shop lineshaft, cylinder side - East Broad Top Railroad & Coal Company, Machine Shop, State Route 994, West of U.S. Route 522, Rockhill Furnace, Huntingdon County, PA

  5. Detail view of flyball governor to Main Steam Engine that ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Detail view of flyball governor to Main Steam Engine that drove the overhead belt and shaft system - East Broad Top Railroad & Coal Company, Machine Shop, State Route 994, West of U.S. Route 522, Rockhill Furnace, Huntingdon County, PA

  6. 35. VIEW OF MAIN DECK ENGINE FLAT, LOOKING AFT AT ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    35. VIEW OF MAIN DECK ENGINE FLAT, LOOKING AFT AT STEAM CHEST AND CYLINDER HEADS. ORIGINAL STEAM FIRE PUMP IS ON PORT SIDE - Steam Schooner WAPAMA, Kaiser Shipyard No. 3 (Shoal Point), Richmond, Contra Costa County, CA

  7. Cassini Main Engine Assembly Cover Flight Management and Performance

    NASA Technical Reports Server (NTRS)

    Somawardhana, Ruwan P.; Millard, Jerry M.

    2010-01-01

    The Cassini spacecraft has performed its four year Prime Mission at Saturn and is currently in orbit at Saturn performing a two year extended mission. 12Its main engine nozzles are susceptible to impact damage from micrometeoroids and on-orbit dust. The spacecraft has an articulating device known as the Main Engine Assembly (MEA) cover which can close and shield the main engines from these threats. The cover opens to allow for main engine burns that are necessary to maintain the trajectory. Periodically updated analyses of potential on-orbit dust hazard threats have resulted in the need to continue to use the MEA cover beyond its intended use and beyond its design life. This paper provides a detailed Systems-level overview of the flight management of the MEA cover device and its flight performance to date.

  8. 12. VIEW FROM MAIN ENTRANCE OF STOVE, ENGINE LATHE, AND ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    12. VIEW FROM MAIN ENTRANCE OF STOVE, ENGINE LATHE, AND GRINDER (L TO R) IN FOREGROUND, SHAFTING ABOVE LOOKING SOUTH. - W. A. Young & Sons Foundry & Machine Shop, On Water Street along Monongahela River, Rices Landing, Greene County, PA

  9. 18. VIEW TOWARD MAIN ENTRANCE OF AMERICAN TOOL ENGINE LATHE, ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    18. VIEW TOWARD MAIN ENTRANCE OF AMERICAN TOOL ENGINE LATHE, JIB CRANE ABOVE-LOOKING NORTH. - W. A. Young & Sons Foundry & Machine Shop, On Water Street along Monongahela River, Rices Landing, Greene County, PA

  10. Space Shuttle Main Engine: Thirty Years of Innovation

    NASA Technical Reports Server (NTRS)

    Jue, F. H.; Hopson, George (Technical Monitor)

    2002-01-01

    The Space Shuttle Main Engine (SSME) is the first reusable, liquid booster engine designed for human space flight. This paper chronicles the 30-year history and achievements of the SSME from authority to proceed up to the latest flight configuration - the Block 2 SSME.

  11. Space Shuttle Main Engine Turbopump Bearing Testing at Marshall Space Flight Center

    NASA Technical Reports Server (NTRS)

    Gibson, Howard; Thom, Robert; Moore, Chip

    2010-01-01

    The Space Shuttle has three main engines that are used for lift off into orbit. These engines are fed propellants by low and high pressure turbopumps on each engine. A main element of the pumps are the bearings supporting the main shaft that spins the turbine and pumps. These bearings must spin at high speeds, support the radial and axial thrust loads, and have high wear resistance without the benefit of lubrication. This paper describes the bearing testing that was done at the Marshall Space Flight Center and the results that were obtained to provide the best bearing design possible for safe and reliable engine performance.

  12. Iterative procedures for space shuttle main engine performance models

    NASA Technical Reports Server (NTRS)

    Santi, L. Michael

    1989-01-01

    Performance models of the Space Shuttle Main Engine (SSME) contain iterative strategies for determining approximate solutions to nonlinear equations reflecting fundamental mass, energy, and pressure balances within engine flow systems. Both univariate and multivariate Newton-Raphson algorithms are employed in the current version of the engine Test Information Program (TIP). Computational efficiency and reliability of these procedures is examined. A modified trust region form of the multivariate Newton-Raphson method is implemented and shown to be superior for off nominal engine performance predictions. A heuristic form of Broyden's Rank One method is also tested and favorable results based on this algorithm are presented.

  13. Space Shuttle Main Engine (SSME) Options for the Future Shuttle

    NASA Technical Reports Server (NTRS)

    Jue, Fred; Kuck, Fritz; McCool, Alex (Technical Monitor)

    2002-01-01

    The main engines for the Future Shuttle will focus on improved safety and operability. Performance enhancements may also be required for vehicle safety purposes to achieve more desirable abort scenarios. This paper discusses the potential improvements that will be considered for implementation into the Future Shuttle. Integrated engine and vehicle health management systems will achieve additional system-level reliability improvements over those currently in development. Advanced instrumentation for detecting leaks, analyzing component wear and degradation, and providing sophisticated operational data will be used for reliable engine control and scheduling maintenance operations. A new nozzle and main combustion chamber (MCC) will reduce failure probability by 50% and allow for higher thrust capability without requiring the entire engine to be redesigned. Turbopump improvements may range from minor component improvements to using 3rd-generation pumps built on the advanced concepts demonstrated by the Integrated Powerhead Development (IPD) program and the Space Launch Initiative (SLI) prototype engines.The main engines for the Future Shuttle will focus on improved safety and operability. Performance enhancements may also be required for vehicle safety purposes to achieve more desirable abort scenarios. This paper discusses the potential improvements that will be considered for implementation into the Future Shuttle. Integrated engine and vehicle health management systems will achieve additional system-level reliability improvements over those currently in development. Advanced instrumentation for detecting leaks, analyzing component wear and degradation, and providing sophisticated operational data will be used for reliable engine control and scheduling maintenance operations. A new nozzle and main combustion chamber (MCC) will reduce failure probability by 50% and allow for higher thrust capability without requiring the entire engine to be redesigned. Turbopump

  14. Advanced Health Management System for the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Davidson, Matt; Stephens, John

    2004-01-01

    Boeing-Canoga Park (BCP) and NASA-Marshall Space Flight Center (NASA-MSFC) are developing an Advanced Health Management System (AHMS) for use on the Space Shuttle Main Engine (SSME) that will improve Shuttle safety by reducing the probability of catastrophic engine failures during the powered ascent phase of a Shuttle mission. This is a phased approach that consists of an upgrade to the current Space Shuttle Main Engine Controller (SSMEC) to add turbomachinery synchronous vibration protection and addition of a separate Health Management Computer (HMC) that will utilize advanced algorithms to detect and mitigate predefined engine anomalies. The purpose of the Shuttle AHMS is twofold; one is to increase the probability of successfully placing the Orbiter into the intended orbit, and the other is to increase the probability of being able to safely execute an abort of a Space Transportation System (STS) launch. Both objectives are achieved by increasing the useful work envelope of a Space Shuttle Main Engine after it has developed anomalous performance during launch and the ascent phase of the mission. This increase in work envelope will be the result of two new anomaly mitigation options, in addition to existing engine shutdown, that were previously unavailable. The added anomaly mitigation options include engine throttle-down and performance correction (adjustment of engine oxidizer to fuel ratio), as well as enhanced sensor disqualification capability. The HMC is intended to provide the computing power necessary to diagnose selected anomalous engine behaviors and for making recommendations to the engine controller for anomaly mitigation. Independent auditors have assessed the reduction in Shuttle ascent risk to be on the order of 40% with the combined system and a three times improvement in mission success.

  15. Studies and analyses of the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Tischer, Alan E.; Glover, R. C.

    1987-01-01

    The primary objectives were to: evaluate ways to maximize the information yield from the current Space Shuttle Main Engine (SSME) condition monitoring sensors, identify additional sensors or monitoring capabilities which would significantly improve SSME data, and provide continuing support of the Main Engine Cost/Operations (MECO) model. In the area of SSME condition monitoring, the principal tasks were a review of selected SSME failure data, a general survey of condition monitoring, and an evaluation of the current engine monitoring system. A computerized data base was developed to assist in modeling engine failure information propagations. Each of the above items is discussed in detail. Also included is a brief discussion of the activities conducted in support of the MECO model.

  16. General view of the Space Shuttle Main Engine (SSME) assembly ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of the Space Shuttle Main Engine (SSME) assembly with the expansion nozzle removed and resting on a cushioned mat on the floor of the SSME Processing Facility. The most prominent features in this view are the Low-Pressure Fuel Turbopump (LPFTP) on the upper left of the engine assembly, the LPFTP Discharge Duct looping around the assembly, the Gimbal Bearing on the top center of the assembly, the Electrical Interface Panel sits just below the Gimbal Bearing and the Low-Pressure Oxidizer Turbopump is mounted on the top right of the engine assembly in this view. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  17. A simplified dynamic model of the Space Shuttle main engine

    NASA Technical Reports Server (NTRS)

    Duyar, Ahmet; Eldem, Vasfi; Merrill, Walter; Guo, Ten-Huei

    1991-01-01

    A simplified model is presented of the space shuttle main engine (SSME) dynamics valid within the range of operation of the engine. This model is obtained by linking the linearized point models obtained at 25 different operating points of SSME. The simplified model was developed for use with a model-based diagnostic scheme for failure detection and diagnostics studies, as well as control design purposes.

  18. Structural dynamic analysis of the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Scott, L. P.; Jamison, G. T.; Mccutcheon, W. A.; Price, J. M.

    1981-01-01

    This structural dynamic analysis supports development of the SSME by evaluating components subjected to critical dynamic loads, identifying significant parameters, and evaluating solution methods. Engine operating parameters at both rated and full power levels are considered. Detailed structural dynamic analyses of operationally critical and life limited components support the assessment of engine design modifications and environmental changes. Engine system test results are utilized to verify analytic model simulations. The SSME main chamber injector assembly is an assembly of 600 injector elements which are called LOX posts. The overall LOX post analysis procedure is shown.

  19. Space Shuttle Main Engine Debris Testing Methodology and Impact Tolerances

    NASA Technical Reports Server (NTRS)

    Gradl, Paul R.; Stephens, Walter

    2005-01-01

    In the wake of the Space Shuttle Columbia disaster every effort is being made to determine the susceptibility of Space Shuttle elements to debris impacts. Ice and frost debris is formed around the aft heat shield closure of the orbiter and liquid hydrogen feedlines. This debris has been observed to liberate upon lift-off of the shuttle and presents potentially dangerous conditions to the Space Shuttle Main Engine. This paper describes the testing done to determine the impact tolerance of the Space Shuttle Main Engine nozzle coolant tubes to ice strikes originating from the launch pad or other parts of the shuttle.

  20. Radial and circumferential flow surveys at the inlet and exit of the Space Shuttle Main Engine High Pressure Fuel Turbine Model

    NASA Astrophysics Data System (ADS)

    Hudson, S. T.; Bordelon, W. J., Jr.; Smith, A. W.; Ramachandran, N.

    1995-01-01

    The main objective of this test was to obtain detailed radial and circumferential flow surveys at the inlet and exit of the SSME High Pressure Fuel Turbine model using three-hole cobra probes, hot-film probes, and a laser velocimeter. The test was designed to meet several objectives. First, the techniques for making laser velocimeter, hot-film probe, and cobra probe measurements in turbine flows were developed and demonstrated. The ability to use the cobra probes to obtain static pressure and, therefore, velocity had to be verified; insertion techniques had to be established for the fragile hot-film probes; and a seeding method had to be established for the laser velocimetry. Once the measurement techniques were established, turbine inlet and exit velocity profiles, temperature profiles, pressure profiles, turbulence intensities, and boundary layer thicknesses were measured at the turbine design point. The blockage effect due to the model inlet and exit total pressure and total temperature rakes on the turbine performance was also studied. A small range of off-design points were run to obtain the profiles and to verify the rake blockage effects off-design. Finally, a range of different Reynolds numbers were run to study the effect of Reynolds number on the various measurements.

  1. General view of a Space Shuttle Main Engine (SSME) mounted ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of a Space Shuttle Main Engine (SSME) mounted on an SSME engine handler, taken in the SSME Processing Facility at Kennedy Space Center. The most prominent feature in this view is the Expansion Nozzle . The rings that loop around the nozzle, vertically in this view, add structural stability to the nozzle walls and are referred to Hatbands. The ring on the left most edge of the nozzle is the Coolant Inlet Manifold. The tubes that branch off and connect to the manifold are Coolant Transfer Ducts and the tubes that terminate with a visible opening at the manifold are Drain Lines. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  2. Closeup view of a Space Shuttle Main Engine (SSME) mounted ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Close-up view of a Space Shuttle Main Engine (SSME) mounted on an SSME engine handler, taken in the SSME Processing Facility at Kennedy Space Center. The most prominent feature in this view is the Expansion Nozzle . The rings that loop around the nozzle, vertically in this view, add structural stability to the nozzle walls and are referred to Hatbands. The ring on the left most edge of the nozzle is the Coolant Inlet Manifold. The tubes that branch off and connect to the manifold are Coolant Transfer Ducts and the tubes that terminate with a visible opening at the manifold are Drain Lines. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

  3. General view of Main Steam Engine for shop lineshaft, valve ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    General view of Main Steam Engine for shop lineshaft, valve chest side (EBT Railroad 1882, A.W. SIMS, SUPT.) - East Broad Top Railroad & Coal Company, Machine Shop, State Route 994, West of U.S. Route 522, Rockhill Furnace, Huntingdon County, PA

  4. 23. BACKING DRUM IN FOREGROUND. MAIN ENGINE STEP DRUM IN ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    23. BACKING DRUM IN FOREGROUND. MAIN ENGINE STEP DRUM IN CENTER. TO RIGHT NOTE CYLINDER, PISTON ROD CROSSHEAD. AT END OF CRANKSHAFT NOTE WRIST PIN AND CRANE DISK. - Dredge CINCINNATI, Docked on Ohio River at foot of Lighthill Street, Pittsburgh, Allegheny County, PA

  5. Holographic flow diagnostics for the Space Shuttle main engine

    NASA Astrophysics Data System (ADS)

    1992-02-01

    Summarized here are the results of an effort to produce holograms of the exhaust from the Space Shuttle Main Engine (SSME) being tested on a test stand at the Marshall Space Flight Center (MSFC). The effort took place from December 1990 to January 1992, during which seven trips were made from MetroLaser to MSFC. A brief outline of each trip is given. Due to the suspension of the SSME program in Huntsville and unexpected complications in resolving safety issues, the proposed holography system was not operated until November 1991. A NASA 100 mW Argon laser was installed in the holography system for an October engine test while these safety issues were being resolved. A video camera shadowgraph was made during this test, which was shut down prematurely after 20 seconds. System problems precluded successful operation of the holography system until the January 1992 engine test. No hologram resulted during this test due to heavy fog conditions around the engine.

  6. 30. Engine controls and valve gear, looking aft on main ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    30. Engine controls and valve gear, looking aft on main (promenade) deck level. Threaded admission valve lift rods (two at immediate left of chronometer) permit adjustment of valve timing in lower and upper admission valves of cylinder (left rod controls lower valve, right rod upper valve). Valve rods are lifted by jaw-like "wipers" during operation. Exhaust valve lift rods and wipers are located to right of chronometer. Crank at extreme right drives valve wiper shaft when engaged to end of eccentric rod, shown under "Crank Indicator" dial. Pair of handles to immediate left of admission valve rods control condenser water valves; handles to right of exhaust valve rods control feedwater flow to boilers from pumps. Gauges indicate boiler pressure (left) and condenser vacuum (right); "Crank Indicator" on wall aids engineer in keeping engine crank off "dead-center" at stop so that engine may be easily restarted. - Ferry TICONDEROGA, Route 7, Shelburne, Chittenden County, VT

  7. Holographic flow diagnostics for the Space Shuttle main engine

    NASA Technical Reports Server (NTRS)

    1992-01-01

    Summarized here are the results of an effort to produce holograms of the exhaust from the Space Shuttle Main Engine (SSME) being tested on a test stand at the Marshall Space Flight Center (MSFC). The effort took place from December 1990 to January 1992, during which seven trips were made from MetroLaser to MSFC. A brief outline of each trip is given. Due to the suspension of the SSME program in Huntsville and unexpected complications in resolving safety issues, the proposed holography system was not operated until November 1991. A NASA 100 mW Argon laser was installed in the holography system for an October engine test while these safety issues were being resolved. A video camera shadowgraph was made during this test, which was shut down prematurely after 20 seconds. System problems precluded successful operation of the holography system until the January 1992 engine test. No hologram resulted during this test due to heavy fog conditions around the engine.

  8. Automatic detection of anomalies in Space Shuttle Main Engine turbopumps

    NASA Astrophysics Data System (ADS)

    Lo, Ching F.; Whitehead, B. A.; Wu, Kewei

    1992-07-01

    A prototype expert system (developed on both PC and Symbolics 3670 lisp machine) for detecting anomalies in turbopump vibration data has been tested with data from ground tests 902-473, 902-501, 902-519, and 904-097 of the Space Shuttle Main Engine (SSME). The expert system has been utilized to analyze vibration data from each of the following SSME components: high-pressure oxidizer turbopump, high-pressure fuel turbopump, low-pressure fuel turbopump, and preburner boost pump. The expert system locates and classifies peaks in the power spectral density of each 0.4-sec window of steady-state data. Peaks representing the fundamental and harmonic frequencies of both shaft rotation and bearing cage rotation are identified by the expert system. Anomalies are then detected on the basis of sequential criteria and two threshold criteria set individually for the amplitude of each of these peaks: a prior threshold used during the first few windows of data in a test, and a posterior threshold used thereafter. In most cases the anomalies detected by the expert system agree with those reported by NASA. The two cases where there is significant disagreement will be further studied and the system design refined accordingly.

  9. Automatic detection of anomalies in Space Shuttle Main Engine turbopumps

    NASA Technical Reports Server (NTRS)

    Lo, Ching F.; Whitehead, B. A.; Wu, Kewei

    1992-01-01

    A prototype expert system (developed on both PC and Symbolics 3670 lisp machine) for detecting anomalies in turbopump vibration data has been tested with data from ground tests 902-473, 902-501, 902-519, and 904-097 of the Space Shuttle Main Engine (SSME). The expert system has been utilized to analyze vibration data from each of the following SSME components: high-pressure oxidizer turbopump, high-pressure fuel turbopump, low-pressure fuel turbopump, and preburner boost pump. The expert system locates and classifies peaks in the power spectral density of each 0.4-sec window of steady-state data. Peaks representing the fundamental and harmonic frequencies of both shaft rotation and bearing cage rotation are identified by the expert system. Anomalies are then detected on the basis of sequential criteria and two threshold criteria set individually for the amplitude of each of these peaks: a prior threshold used during the first few windows of data in a test, and a posterior threshold used thereafter. In most cases the anomalies detected by the expert system agree with those reported by NASA. The two cases where there is significant disagreement will be further studied and the system design refined accordingly.

  10. Research Study: Space Shuttle Main Engine Plume Flowfield Model

    NASA Technical Reports Server (NTRS)

    Bender, Robert L.

    1988-01-01

    The initial research effort was an in-depth analysis of the shuttle main engine plumes in an effort to improve the flowfield model and to enhance shuttle base heating equipment predictions during ascent. A prediction methodology code was developed incorporating the improved plume model into a predictive tool which could consider different trajectoreis and engine perfromance variables. Various plume flow model improvement studies were ongoing at the time of the 51-L accident. Since that time, base heating and plume methodology improvements have continued as part of the overall emphasis on Shuttle design assurance before resuming flight schedule.

  11. Nonlinear rotordynamics analysis. [Space Shuttle Main Engine turbopumps

    NASA Technical Reports Server (NTRS)

    Noah, Sherif T.

    1991-01-01

    Effective analysis tools were developed for predicting the nonlinear rotordynamic behavior of the Space Shuttle Main Engine (SSME) turbopumps under steady and transient operating conditions. Using these methods, preliminary parametric studies were conducted on both generic and actual HPOTP (high pressure oxygen turbopump) models. In particular, a novel modified harmonic balance/alternating Fourier transform (HB/AFT) method was developed and used to conduct a preliminary study of the effects of fluid, bearing and seal forces on the unbalanced response of a multi-disk rotor in the presence of bearing clearances. The method makes it possible to determine periodic, sub-, super-synchronous and chaotic responses of a rotor system. The method also yields information about the stability of the obtained response, thus allowing bifurcation analyses. This provides a more effective capability for predicting the response under transient conditions by searching in proximity of resonance peaks. Preliminary results were also obtained for the nonlinear transient response of an actual HPOTP model using an efficient, newly developed numerical method based on convolution integration. Currently, the HB/AFT is being extended for determining the aperiodic response of nonlinear systems. Initial results show the method to be promising.

  12. Automatic detection of anomalies in Space Shuttle Main Engine turbopumps

    NASA Technical Reports Server (NTRS)

    Lo, Ching F. (Principal Investigator); Whitehead, Bruce; Wu, Kewei; Rogers, George

    1992-01-01

    A prototype expert system for detecting anomalies in turbopump vibration data has been tested with data from ground tests 902-473, 902-501 902-519, and 904-097 of the Space Shuttle Main Engine!nc (SSME). The expert system has been utilized to analyze vibration ion data from each of the following SSME components: pressure oxidizer turbopump, high-pressure fuel turbo pump, low-pressure fuel turbopump, and preburner boost pump. The expert system locates and classifies peaks in the power spectral density of each 0.4 s window of steady-state data. Peaks representing the fundamental and harmonic frequencies of both shaft rotation and bearing cage rotation are identified by the expert system. Anomalies are then detected on the basis of of two thresholds set individually for the amplitude of each of these peaks: a prior threshold used during the first few windows of data in a test, and a posterior threshold used thereafter. In most cases the anomalies detected by the expert system agree with those reported by NASA. The two cases where there is significant disagreement will be further studied and the system design refined accordingly.

  13. 27. VIEW FROM AFT OF MAIN HOISTING ENGINE WITH HOISTING ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    27. VIEW FROM AFT OF MAIN HOISTING ENGINE WITH HOISTING DRUM IN FOREGROUND. NOTE MAIN HOISTING DRUM IS A STEP DRUM, WITH TWO DIAMETERS ON DRUM. WHEN BUCKET IS IN WATER THE CABLE IS ON THE SMALLER STEP, AS PICTURED, GIVING MORE POWER TO THE LINE. THE CABLE STEPS TO LARGER DIAMETER WHEN BUCKET IS OUT OF WATER, WHERE SPEED IS MORE IMPORTANT THAN POWER. SMALLER BACKING DRUM IN BACKGROUND. - Dredge CINCINNATI, Docked on Ohio River at foot of Lighthill Street, Pittsburgh, Allegheny County, PA

  14. TVC actuator model. [for the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Baslock, R. W.

    1977-01-01

    A prototype Space Shuttle Main Engine (SSME) Thrust Vector Control (TVC) Actuator analog model was successfully completed. The prototype, mounted on five printed circuit (PC) boards, was delivered to NASA, checked out and tested using a modular replacement technique on an analog computer. In all cases, the prototype model performed within the recording techniques of the analog computer which is well within the tolerances of the specifications.

  15. Investigations of ice formation in the Space Shuttle Main Engine 0209 main injector coolant cavity

    NASA Technical Reports Server (NTRS)

    Richards, D. R.; Charklwick, D. M.

    1991-01-01

    Severe main combustion chamber wall and main injector baffle element deterioration occurred during tests of Space Shuttle Main Engine 0209. One of the possible causes considered is ice formation and blockage of coolant to these components, resulting from the mixing of leaking hot turbine exhaust gas (hydrogen rich steam) and hydrogen coolant in the injector coolant cavity. The plausibility of ice blockage is investigated through simple mixing calculations for hot gas and hydrogen, investigation of condensation and water droplet formation, calculation of the freezing times for droplets, and the prediction of ice layer thicknesses. It is concluded that condensation and droplet formation can occur, and small water droplets that form can freeze very quickly when in contact with the cold coolant cavity surfaces. Copnservative analysis predicts, however, that the maximum thickness of the ice layers formed is too small to result in significant blockage of the coolant flow.

  16. Study of methods for applying and enhancing transfer film coatings of polytetrafluoroethylene (PTEE) to Space Shuttle Main Engine (SSME) High Pressure Oxygen Turbo Pump (HPOTP) bearings

    NASA Technical Reports Server (NTRS)

    Kannel, J. W.; Dufrane, K. F.; Zugaro, F. F.

    1981-01-01

    Machines were constructed and evaluated for burnishing polytetrafluoroethylene on balls for use in the high pressure oxygen turbopump (HPOTP). The most positive performance was obtained with single-ball burnishing, but one technique for burnishing three balls simultaneously holds promise. Evaluations of the coatings in a HPOTP bearing of earlier design (employed smaller diameter balls) showed very little life enhancement before high torque and ball and race wear initiated. Other coating techniques, such as molybdenum disulfide combined with PTFE transfer films, hold promise for providing the more durable quantities of solid lubricant needed for the bearings.

  17. Space Shuttle Main Engine: Advanced Health Monitoring System

    NASA Technical Reports Server (NTRS)

    Singer, Chirs

    1999-01-01

    The main gola of the Space Shuttle Main Engine (SSME) Advanced Health Management system is to improve flight safety. To this end the new SSME has robust new components to improve the operating margen and operability. The features of the current SSME health monitoring system, include automated checkouts, closed loop redundant control system, catastropic failure mitigation, fail operational/ fail-safe algorithms, and post flight data and inspection trend analysis. The features of the advanced health monitoring system include: a real time vibration monitor system, a linear engine model, and an optical plume anomaly detection system. Since vibration is a fundamental measure of SSME turbopump health, it stands to reason that monitoring the vibration, will give some idea of the health of the turbopumps. However, how is it possible to avoid shutdown, when it is not necessary. A sensor algorithm has been developed which has been exposed to over 400 test cases in order to evaluate the logic. The optical plume anomaly detection (OPAD) has been developed to be a sensitive monitor of engine wear, erosion, and breakage.

  18. Laser velocimeter measurements of the flow downstream of the Space Shuttle Main Engine high pressure oxidizer turbopump first-stage turbine nozzle

    NASA Technical Reports Server (NTRS)

    Ferguson, T. V.; Havskjold, G. L.; Rojas, L.

    1988-01-01

    A laser two-focus velocimeter was used in an open-loop water test facility in order to map the flowfield downstream of the SSME's high-pressure oxidizer turbopump first-stage turbine nozzle; attention was given to the effects of the upstream strut-downstream nozzle configuration on the flow at the rotor inlet, in order to estimate dynamic loads on the first-stage rotor blades. Velocity and flow angles were plotted as a function of circumferential position, and were found to clearly display the periodic behavior of the wake flow field. The influence of the upstream centerbody-supporting struts on the vane nozzle wake pattern was evident.

  19. Liquid Oxygen/Liquid Methane Ascent Main Engine Technology Development

    NASA Technical Reports Server (NTRS)

    Robinson, Joel W.; Stephenson, David D.

    2008-01-01

    The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LO2)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon the Exploration Systems Architecture Study (ESAS). The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. The current application considering this technology is the lunar ascent main engine (AME). AME is anticipated to be an expendable, pressure-fed engine to provide ascent from the moon at the completion of a 210 day lunar stay. The engine is expected to produce 5,500 lbf (24,465 N) thrust with variable inlet temperatures due to the cryogenic nature of the fuel and oxidizer. The primary technology risks include establishing reliable and robust ignition in vacuum conditions, maximizing specific impulse, developing rapid start capability for the descent abort, providing the capability for two starts and producing a total engine bum time over 500 seconds. This paper will highlight the efforts of the Marshall Space Flight Center (MSFC) in addressing risk reduction activities for this technology.

  20. A Basic Comparison of the Space Shuttle Main Engine and the J-2X Engine

    NASA Technical Reports Server (NTRS)

    Ayer, Adam

    2007-01-01

    With the introduction of the new manned space effort through the Constellation Program, there is an interest to have a basic comparison of the current Space Shuttle Main Engine (SSME) to the J-2X engine used for the second stage of both the Ares I and Ares V rockets. This paper seeks to compare size, weight and thrust capabilities while drawing simple conclusions on differences between the two engines.

  1. Turbine blade structural dynamic analysis. [for space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Dickerson, E. O.

    1980-01-01

    The paper presents structural dynamic analysis and test results for the Space Shuttle Main Engine turbine blades. Athough these blades are designed to avoid coincidence of natural frequencies with harmonic excitation forces, the complexity of the turbine hardware, its nonlinearities and lack of information regarding the forcing function have led to fatigue failures. A comparison of single-blade analysis and test modal frequencies, shapes, and stresses is given; analysis techniques to describe the forcing function, compute dynamic responses, and incorporate the nonlinearities of Coulomb-friction dampers are presented. Recommendations are made for new research to improve forcing function computations and structural damping estimates used in the analysis.

  2. Non-intrusive speed sensor. [space shuttle main engine turbopumps

    NASA Technical Reports Server (NTRS)

    Maram, J.; Wyett, L.

    1984-01-01

    A computerized literature search was performed to identify candidate technologies for remote, non-intrusive speed sensing applications in Space Shuttle Main Engine (SSME) turbopumps. The three most promising technologies were subjected to experimental evaluation to quantify their performance characteristics under the harsh environmental requirements within the turbopumps. Although the infrared and microwave approaches demonstrated excellent cavitation immunity in laboratory tests, the variable-source magnetic speed sensor emerged as the most viable approach. Preliminary design of this speed sensor encountered no technical obstacles and resulted in viable and feasible speed nut, sensor housing, and sensor coil designs.

  3. Space Shuttle Main Engine nozzle thermal protection system

    NASA Technical Reports Server (NTRS)

    Nordlund, R. M.

    1985-01-01

    Two of the three Space Shuttle Main Engine (SSME) nozzles are exposed to significant reentry aeroheating loads. To ensure reusability of the Nozzle Assembly, the nozzle primary structure must not exceed specific temperature limits. Due to the thermal, pressure, and dynamic flexing of the nozzle during a mission cycle, an appropriate insulating system must have significant flexibility. Recent missions have demonstrated nozzle reentry aeroheating rates and heat loads much higher than predictions, higher than the capability of the original insulating system. A new insulating system has been developed using similar materials in an aerodynamically 'smooth' shape to both reduce the incoming heating and increase radiation cooling.

  4. Space shuttle main engine fault detection using neural networks

    NASA Technical Reports Server (NTRS)

    Bishop, Thomas; Greenwood, Dan; Shew, Kenneth; Stevenson, Fareed

    1991-01-01

    A method for on-line Space Shuttle Main Engine (SSME) anomaly detection and fault typing using a feedback neural network is described. The method involves the computation of features representing time-variance of SSME sensor parameters, using historical test case data. The network is trained, using backpropagation, to recognize a set of fault cases. The network is then able to diagnose new fault cases correctly. An essential element of the training technique is the inclusion of randomly generated data along with the real data, in order to span the entire input space of potential non-nominal data.

  5. High Moisture Corn Evaluated for Northern Maine

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Profitable rotation crops that can grow in cool, northern Maine climates are needed to sustain the diversity of potato systems. A field experiment was conducted to determine whether three high moisture corn hybrids were suitable for harvest as a short season rotation crop. Yield and grain moisture...

  6. Space Shuttle Main Engine (SSME) Systems Operation Overview and Evolution

    NASA Technical Reports Server (NTRS)

    Benefield, Philip A.; Kan, Kenneth C.

    2010-01-01

    The Space Shuttle Main Engine (SSME) is a large thrust class, reusable, staged combustion cycle rocket engine employing liquid hydrogen and liquid oxygen propellants. A cluster of three SSMEs is used on every space shuttle mission to propel the space shuttle orbiter vehicle into low earth orbit. Development of the SSME began in the early 70's and the first flight of the space shuttle occurred in 1981. Today, the SSME has accrued over one million seconds of ground test and flight operational time, launching 129 space shuttle missions. The systems operation of the SSME was developed and evolved to support the specific requirements of the Space Shuttle Program (SSP). This paper provides a systems operation overview of the SSME, including: engine cycle, propellant flowpaths, and major components; control system; operations during pre-start, start, mainstage, and shutdown phases; launch commit criteria (LCCs) and operational redlines. Furthermore, this paper will discuss how changes to the SSME over its history have impacted systems operations.

  7. Summary of Results from Space Shuttle Main Engine Off-Nominal Testing

    NASA Technical Reports Server (NTRS)

    Horton, James F.; Megivern, Jeffrey M.; McNutt, Leslie M.

    2011-01-01

    This paper is a summary of Space Shuttle Main Engine (SSME) off-nominal testing that occurred during 2008 and 2009. During the last two years of planned SSME testing at Stennis Space Center, Pratt & Whitney Rocketdyne worked with their NASA MSFC customer to systematically identify, develop, assess, and implement challenging test objectives in order to expand the knowledge of one of the world s most reliable and highly tested large rocket engine. The objectives successfully investigated three main areas of interest expanding engine performance margins, demonstrating system operational capabilities, and establishing ground work for new rocket engine technology. The testing gave the Space Shuttle Program new options to safely fly out the flight manifest and provided Pratt & Whitney Rocketdyne and NASA new insight into the operational capabilities of the SSME, capabilities which can be used in assessing potential future applications of the RS-25 engine.

  8. Space Shuttle Main Engine modal test correlation and optimization

    NASA Astrophysics Data System (ADS)

    Stec, Robert C.; Gupta, Viney K.; Chaney, Lisa; Haworth, John M.

    1993-04-01

    A cost-effective software testbed under development is described for updating and validating Finite-Element Models (FEMs) to certify large-scale Space Shuttle Main Engine (SSME) STARDYNE and NASTRAN FEMs against modal test data. The long-term objectives of the testbed are to provide timely support and certification of SSME components using modal testing: certify large-scale structures such as the SSME using modal survey tests, update FEMs for model validation against test frequencies and mode shapes, verify the load factors for design loads assumed to determine structural integrity, demonstrate the Rocketdyne software testbed based on state-of-the art methods - optimization, static/dynamic reduction, sparse Lanczos solvers and iterative perturbation algorithms, and to identify future enhancements and applications for the National Aeronautics and Space Administration (NASA)-Rocketdyne testbed "FEMOPT" developed for Space Station and SSME model certification.

  9. A History of Welding on the Space Shuttle Main Engine (1975 to 2010)

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank R.; Russell, Carolyn K.

    2010-01-01

    The Space Shuttle Main Engine (SSME) is a high performance, throttleable, liquid hydrogen fueled rocket engine. High thrust and specific impulse (Isp) are achieved through a staged combustion engine cycle, combined with high combustion pressure (approx.3000psi) generated by the two-stage pump and combustion process. The SSME is continuously throttleable from 67% to 109% of design thrust level. The design criteria for this engine maximize performance and weight, resulting in a 7,800 pound rocket engine that produces over a half million pounds of thrust in vacuum with a specific impulse of 452/sec. It is the most reliable rocket engine in the world, accumulating over one million seconds of hot-fire time and achieving 100% flight success in the Space Shuttle program. A rocket engine with the unique combination of high reliability, performance, and reusability comes at the expense of manufacturing simplicity. Several innovative design features and fabrication techniques are unique to this engine. This is as true for welding as any other manufacturing process. For many of the weld joints it seemed mean cheating physics and metallurgy to meet the requirements. This paper will present a history of the welding used to produce the world s highest performance throttleable rocket engine.

  10. Aft Engine shop worker removes a heat shield on Columbia's main engines

    NASA Technical Reports Server (NTRS)

    2002-01-01

    KENNEDY SPACE CENTER, FLA. -- Doug Buford, with the Aft Engine shop, works at removing a heat shield on Columbia, in the Orbiter Processing Facility. After small cracks were discovered on the LH2 Main Propulsion System (MPS) flow liners in two other orbiters, program managers decided to move forward with inspections on Columbia before clearing it for flight on STS-107. After removal of the heat shields, the three main engines will be removed. Inspections of the flow liners will follow. The July 19 launch of Columbia on STS-107 has been delayed a few weeks

  11. Aft Engine shop worker removes a heat shield on Columbia's main engines

    NASA Technical Reports Server (NTRS)

    2002-01-01

    KENNEDY SPACE CENTER, FLA. - Doug Buford, with the Aft Engine shop, works at removing a heat shield on Columbia, in the Orbiter Processing Facility. After small cracks were discovered on the LH2 Main Propulsion System (MPS) flow liners in two other orbiters, program managers decided to move forward with inspections on Columbia before clearing it for flight on STS-107. After removal of the heat shields, the three main engines will be removed. Inspections of the flow liners will follow. The July 19 launch of Columbia on STS-107 has been delayed a few weeks

  12. Duct flow nonuniformities for Space Shuttle Main Engine (SSME)

    NASA Technical Reports Server (NTRS)

    1987-01-01

    A three-duct Space Shuttle Main Engine (SSME) Hot Gas Manifold geometry code was developed for use. The methodology of the program is described, recommendations on its implementation made, and an input guide, input deck listing, and a source code listing provided. The code listing is strewn with an abundance of comments to assist the user in following its development and logic. A working source deck will be provided. A thorough analysis was made of the proper boundary conditions and chemistry kinetics necessary for an accurate computational analysis of the flow environment in the SSME fuel side preburner chamber during the initial startup transient. Pertinent results were presented to facilitate incorporation of these findings into an appropriate CFD code. The computation must be a turbulent computation, since the flow field turbulent mixing will have a profound effect on the chemistry. Because of the additional equations demanded by the chemistry model it is recommended that for expediency a simple algebraic mixing length model be adopted. Performing this computation for all or selected time intervals of the startup time will require an abundance of computer CPU time regardless of the specific CFD code selected.

  13. Framework for a space shuttle main engine health monitoring system

    NASA Technical Reports Server (NTRS)

    Hawman, Michael W.; Galinaitis, William S.; Tulpule, Sharayu; Mattedi, Anita K.; Kamenetz, Jeffrey

    1990-01-01

    A framework developed for a health management system (HMS) which is directed at improving the safety of operation of the Space Shuttle Main Engine (SSME) is summarized. An emphasis was placed on near term technology through requirements to use existing SSME instrumentation and to demonstrate the HMS during SSME ground tests within five years. The HMS framework was developed through an analysis of SSME failure modes, fault detection algorithms, sensor technologies, and hardware architectures. A key feature of the HMS framework design is that a clear path from the ground test system to a flight HMS was maintained. Fault detection techniques based on time series, nonlinear regression, and clustering algorithms were developed and demonstrated on data from SSME ground test failures. The fault detection algorithms exhibited 100 percent detection of faults, had an extremely low false alarm rate, and were robust to sensor loss. These algorithms were incorporated into a hierarchical decision making strategy for overall assessment of SSME health. A preliminary design for a hardware architecture capable of supporting real time operation of the HMS functions was developed. Utilizing modular, commercial off-the-shelf components produced a reliable low cost design with the flexibility to incorporate advances in algorithm and sensor technology as they become available.

  14. Analysis of the Space Shuttle main engine simulation

    NASA Technical Reports Server (NTRS)

    Deabreu-Garcia, J. Alex; Welch, John T.

    1993-01-01

    This is a final report on an analysis of the Space Shuttle Main Engine Program, a digital simulator code written in Fortran. The research was undertaken in ultimate support of future design studies of a shuttle life-extending Intelligent Control System (ICS). These studies are to be conducted by NASA Lewis Space Research Center. The primary purpose of the analysis was to define the means to achieve a faster running simulation, and to determine if additional hardware would be necessary for speeding up simulations for the ICS project. In particular, the analysis was to consider the use of custom integrators based on the Matrix Stability Region Placement (MSRP) method. In addition to speed of execution, other qualities of the software were to be examined. Among these are the accuracy of computations, the useability of the simulation system, and the maintainability of the program and data files. Accuracy involves control of truncation error of the methods, and roundoff error induced by floating point operations. It also involves the requirement that the user be fully aware of the model that the simulator is implementing.

  15. Embedded expert system for space shuttle main engine maintenance

    NASA Technical Reports Server (NTRS)

    Pooley, J.; Thompson, W.; Homsley, T.; Teoh, W.; Jones, J.; Lewallen, P.

    1987-01-01

    The SPARTA Embedded Expert System (SEES) is an intelligent health monitoring system that directs analysis by placing confidence factors on possible engine status and then recommends a course of action to an engineer or engine controller. The technique can prevent catastropic failures or costly rocket engine down time because of false alarms. Further, the SEES has potential as an on-board flight monitor for reusable rocket engine systems. The SEES methodology synergistically integrates vibration analysis, pattern recognition and communications theory techniques with an artificial intelligence technique - the Embedded Expert System (EES).

  16. Update on development of the Space Shuttle main engine /as of 5 May 1977/

    NASA Technical Reports Server (NTRS)

    Johnson, J. R.

    1977-01-01

    The development and testing of the Space Shuttle main engine are described. The preburners, main injector, main combustion chamber, and 35:1 expansion ratio test nozzle were successfully run at full power level (109 percent of rated power level). Integral combustion stability aids damped induced instability oscillations within 6 milliseconds. Three significant turbomachinery problems were identified and solved during the past year. These problems involved high-pressure fuel turbopump subsynchronous whirl, severe overheating of the turbine bearing and components and, in the high-pressure oxidizer turbopump, burning that first occurred in the drain cavity downstream of the primary oxidizer seal.

  17. Project Morpheus Main Engine Development and Preliminary Flight Testing

    NASA Technical Reports Server (NTRS)

    Morehead, Robert L.

    2011-01-01

    A LOX/Methane rocket engine was developed for a prototype terrestrial lander and then used to fly the lander at Johnson Space Center. The development path of this engine is outlined, including unique items such as variable acoustic damping and variable film cooling.

  18. Combustion Stability Characteristics of the Project Morpheus Liquid Oxygen / Liquid Methane Main Engine

    NASA Technical Reports Server (NTRS)

    Melcher, John C.; Morehead, Robert L.

    2014-01-01

    The project Morpheus liquid oxygen (LOX) / liquid methane (LCH4) main engine is a Johnson Space Center (JSC) designed 5,000 lbf-thrust, 4:1 throttling, pressure-fed cryogenic engine using an impinging element injector design. The engine met or exceeded all performance requirements without experiencing any in- ight failures, but the engine exhibited acoustic-coupled combustion instabilities during sea-level ground-based testing. First tangential (1T), rst radial (1R), 1T1R, and higher order modes were triggered by conditions during the Morpheus vehicle derived low chamber pressure startup sequence. The instability was never observed to initiate during mainstage, even at low power levels. Ground-interaction acoustics aggravated the instability in vehicle tests. Analysis of more than 200 hot re tests on the Morpheus vehicle and Stennis Space Center (SSC) test stand showed a relationship between ignition stability and injector/chamber pressure. The instability had the distinct characteristic of initiating at high relative injection pressure drop at low chamber pressure during the start sequence. Data analysis suggests that the two-phase density during engine start results in a high injection velocity, possibly triggering the instabilities predicted by the Hewitt stability curves. Engine ignition instability was successfully mitigated via a higher-chamber pressure start sequence (e.g., 50% power level vs 30%) and operational propellant start temperature limits that maintained \\cold LOX" and \\warm methane" at the engine inlet. The main engine successfully demonstrated 4:1 throttling without chugging during mainstage, but chug instabilities were observed during some engine shutdown sequences at low injector pressure drop, especially during vehicle landing.

  19. Multidisciplinary analysis of Skylab photography for highway engineering purposes. [Maine

    NASA Technical Reports Server (NTRS)

    Stoeckeler, E. G.; Woodman, R. G. (Principal Investigator); Farrell, R. S.

    1975-01-01

    The author has identified the following significant results. The greatly increased resolution of ground features by Skylab as compared with LANDSAT is considered to be best in the S190B high resolution film, followed by S190A camera stations 4, 5, and 6 respectfully. Results of the study of vegetation damage sites using data derived from S190A film were disappointing. The major cause of detection problems is the graininess of the CIR film. Good results were achieved for the hydrology-land use study. Both camera systems gave better agreement with the ground truth than did LANDSAT imagery. Surficial geology and glacial landform areas were clearly visible in single scenes. Several previously unmapped or unknown features were detected, especially in eastern coastal Maine.

  20. History and Benefits of Engine Level Testing Throughout the Space Shuttle Main Engine Program

    NASA Technical Reports Server (NTRS)

    VanHooser, Katherine; Kan, Kenneth; Maddux, Lewis; Runkle, Everett

    2010-01-01

    Rocket engine testing is important throughout a program s life and is essential to the overall success of the program. Space Shuttle Main Engine (SSME) testing can be divided into three phases: development, certification, and operational. Development tests are conducted on the basic design and are used to develop safe start and shutdown transients and to demonstrate mainstage operation. This phase helps form the foundation of the program, demands navigation of a very steep learning curve, and yields results that shape the final engine design. Certification testing involves multiple engine samples and more aggressive test profiles that explore the boundaries of the engine to vehicle interface requirements. The hardware being tested may have evolved slightly from that in the development phase. Operational testing is conducted with mature hardware and includes acceptance testing of flight assets, resolving anomalies that occur in flight, continuing to expand the performance envelope, and implementing design upgrades. This paper will examine these phases of testing and their importance to the SSME program. Examples of tests conducted in each phase will also be presented.

  1. High Performance Arcjet Engines

    NASA Technical Reports Server (NTRS)

    Kennel, Elliot B.; Ivanov, Alexey Nikolayevich; Nikolayev, Yuri Vyacheslavovich

    1994-01-01

    This effort sought to exploit advanced single crystal tungsten-tantalum alloy material for fabrication of a high strength, high temperature arcjet anode. The use of this material is expected to result in improved strength, temperature resistance, and lifetime compared to state of the art polycrystalline alloys. In addition, the use of high electrical and thermal conductivity carbon-carbon composites was considered, and is believed to be a feasible approach. Highly conductive carbon-carbon composite anode capability represents enabling technology for rotating-arc designs derived from the Russian Scientific Research Institute of Thermal Processes (NIITP) because of high heat fluxes at the anode surface. However, for US designs the anode heat flux is much smaller, and thus the benefits are not as great as in the case of NIITP-derived designs. Still, it does appear that the tensile properties of carbon-carbon can be even better than those of single crystal tungsten alloys, especially when nearly-single-crystal fibers such as vapor grown carbon fiber (VGCF) are used. Composites fabricated from such materials must be coated with a refractory carbide coating in order to ensure compatibility with high temperature hydrogen. Fabrication of tungsten alloy single crystals in the sizes required for fabrication of an arcjet anode has been shown to be feasible. Test data indicate that the material can be expected to be at least the equal of W-Re-HfC polycrystalline alloy in terms of its tensile properties, and possibly superior. We are also informed by our colleagues at Scientific Production Association Luch (NP0 Luch) that it is possible to use Russian technology to fabricate polycrystalline W-Re-HfC or other high strength alloys if desired. This is important because existing engines must rely on previously accumulated stocks of these materials, and a fabrication capability for future requirements is not assured.

  2. High Efficiency Engine Technologies Program

    SciTech Connect

    Rich Kruiswyk

    2010-07-13

    Caterpillar's Product Development and Global Technology Division carried out a research program on waste heat recovery with support from DOE (Department of Energy) and the DOE National Energy Technology Laboratory. The objective of the program was to develop a new air management and exhaust energy recovery system that would demonstrate a minimum 10% improvement in thermal efficiency over a base heavy-duty on-highway diesel truck engine. The base engine for this program was a 2007 C15 15.2L series-turbocharged on-highway truck engine with a LPL (low-pressure loop) exhaust recirculation system. The focus of the program was on the development of high efficiency turbomachinery and a high efficiency turbocompound waste heat recovery system. The focus of each area of development was as follows: (1) For turbine stages, the focus was on investigation and development of technologies that would improve on-engine exhaust energy utilization compared to the conventional radial turbines in widespread use today. (2) For compressor stages, the focus was on investigating compressor wheel design parameters beyond the range typically utilized in production, to determine the potential efficiency benefits thereof. (3) For turbocompound, the focus was on the development of a robust bearing system that would provide higher bearing efficiencies compared to systems used in turbocompound power turbines in production. None of the turbocharger technologies investigated involved addition of moving parts, actuators, or exotic materials, thereby increasing the likelihood of a favorable cost-value tradeoff for each technology. And the turbocompound system requires less hardware addition than competing bottoming cycle technologies, making it a more attractive solution from a cost and packaging standpoint. Main outcomes of the program are as follows: (1) Two turbine technologies that demonstrated up to 6% improvement in turbine efficiency on gas stand and 1-3% improvement in thermal efficiency in

  3. Combustion Stability Characteristics of the Project Morpheus Liquid Oxygen/Liquid Methane Main Engine

    NASA Technical Reports Server (NTRS)

    Melcher, J. C.; Morehead, Robert L.

    2014-01-01

    The Project Morpheus liquid oxygen (LOX) / liquid methane rocket engines demonstrated acousticcoupled combustion instabilities during sea-level ground-based testing at the NASA Johnson Space Center (JSC) and Stennis Space Center (SSC). High-amplitude, 1T, 1R, 1T1R (and higher order) modes appear to be triggered by injector conditions. The instability occurred during the Morpheus-specific engine ignition/start sequence, and did demonstrate the capability to propagate into mainstage. However, the instability was never observed to initiate during mainstage, even at low power levels. The Morpheus main engine is a JSC-designed 5,000 lbf-thrust, 4:1 throttling, pressure-fed cryogenic engine using an impinging element injector design. Two different engine designs, named HD4 and HD5, and two different builds of the HD4 engine all demonstrated similar instability characteristics. Through the analysis of more than 200 hot fire tests on the Morpheus vehicle and SSC test stand, a relationship between ignition stability and injector/chamber pressure was developed. The instability has the distinct characteristic of initiating at high relative injection pressure drop (dP) at low chamber pressure (Pc); i.e., instabilities initiated at high dP/Pc at low Pc during the start sequence. The high dP/Pc during start results during the injector /chamber chill-in, and is enhanced by hydraulic flip in the injector orifice elements. Because of the fixed mixture ratio of the existing engine design (the main valves share a common actuator), it is not currently possible to determine if LOX or methane injector dP/Pc were individual contributors (i.e., LOX and methane dP/Pc typically trend in the same direction within a given test). The instability demonstrated initiation characteristic of starting at or shortly after methane injector chillin. Colder methane (e.g., sub-cooled) at the injector inlet prior to engine start was much more likely to result in an instability. A secondary effect of LOX

  4. Space Shuttle main engine turbopump bearing assessment program

    NASA Astrophysics Data System (ADS)

    Breithaupt, B. Spiegel

    1994-03-01

    This report documents the work done on the bearing assessment program over the past two and a half years. The objective of the program is to develop a nondestructive evaluation system for the SSME HPOTP's which would be used to detect anomalies in installed bearings without engine disassembly. Data bases of various signatures are obtained by slowly turning the pump shafts before and after an engine firing. These signatures are then analyzed and compared to the original signatures to more accurately predict bearing wear.

  5. Space Shuttle main engine turbopump bearing assessment program

    NASA Technical Reports Server (NTRS)

    Breithaupt, B. Spiegel

    1994-01-01

    This report documents the work done on the bearing assessment program over the past two and a half years. The objective of the program is to develop a nondestructive evaluation system for the SSME HPOTP's which would be used to detect anomalies in installed bearings without engine disassembly. Data bases of various signatures are obtained by slowly turning the pump shafts before and after an engine firing. These signatures are then analyzed and compared to the original signatures to more accurately predict bearing wear.

  6. Thermal-structural analyses of Space Shuttle Main Engine (SSME) hot section components

    NASA Technical Reports Server (NTRS)

    Abdul-Aziz, Ali; Thompson, Robert L.

    1988-01-01

    Three dimensional nonlinear finite element heat transfer and structural analyses were performed for the first stage high pressure fuel turbopump (HPFTP) blade of the space shuttle main engine (SSME). Directionally solidified (DS) MAR-M 246 and single crystal (SC) PWA-1480 material properties were used for the analyses. Analytical conditions were based on a typical test stand engine cycle. Blade temperature and stress strain histories were calculated by using the MARC finite element computer code. The structural response of an SSME turbine blade was assessed and a greater understanding of blade damage mechanisms, convective cooling effects, and thermal mechanical effects was gained.

  7. Thermal finite-element analysis of space shuttle main engine turbine blade

    NASA Technical Reports Server (NTRS)

    Abdul-Aziz, Ali; Tong, Michael T.; Kaufman, Albert

    1987-01-01

    Finite-element, transient heat transfer analyses were performed for the first-stage blades of the space shuttle main engine (SSME) high-pressure fuel turbopump. The analyses were based on test engine data provided by Rocketdyne. Heat transfer coefficients were predicted by performing a boundary-layer analysis at steady-state conditions with the STAN5 boundary-layer code. Two different peak-temperature overshoots were evaluated for the startup transient. Cutoff transient conditions were also analyzed. A reduced gas temperature profile based on actual thermocouple data was also considered. Transient heat transfer analyses were conducted with the MARC finite-element computer code.

  8. Thermal finite-element analysis of space shuttle main engine turbine blade

    SciTech Connect

    Abdul-Aziz, A.; Tong, M.T.; Kaufman, A.

    1987-10-01

    Finite-element, transient heat transfer analyses were performed for the first-stage blades of the space shuttle main engine (SSME) high-pressure fuel turbopump. The analyses were based on test engine data provided by Rocketdyne. Heat transfer coefficients were predicted by performing a boundary-layer analysis at steady-state conditions with the STAN5 boundary-layer code. Two different peak-temperature overshoots were evaluated for the startup transient. Cutoff transient conditions were also analyzed. A reduced gas temperature profile based on actual thermocouple data was also considered. Transient heat transfer analyses were conducted with the MARC finite-element computer code.

  9. Thin film heat flux sensor for Space Shuttle Main Engine turbine environment

    NASA Technical Reports Server (NTRS)

    Will, Herbert

    1991-01-01

    The Space Shuttle Main Engine (SSME) turbine environment stresses engine components to their design limits and beyond. The extremely high temperatures and rapid temperature cycling can easily cause parts to fail if they are not properly designed. Thin film heat flux sensors can provide heat loading information with almost no disturbance of gas flows or of the blade. These sensors can provide steady state and transient heat flux information. A thin film heat flux sensor is described which makes it easier to measure small temperature differences across very thin insulating layers.

  10. Space Shuttle Main Engine: Part Number RS007001

    NASA Technical Reports Server (NTRS)

    Guinzburg, A.

    1977-01-01

    Topics considered include: low-pressure oxidizer turbopump; low-pressure fuel turbopump; high-pressure oxidizer turbopump; high-pressure oxidizer turbopump turbine; high-pressure fuel turbopump; and SSME propellant flow schematic.

  11. Space Shuttle Main Engine Joint Data List Applying Today's Desktop Technologies to Facilitate Engine Processing

    NASA Technical Reports Server (NTRS)

    Jacobs, Kenneth; Drobnick, John; Krell, Don; Neuhart, Terry; McCool, A. (Technical Monitor)

    2001-01-01

    Boeing-Rocketdyne's Space Shuttle Main Engine (SSME) is the world's first large reusable liquid rocket engine. The space shuttle propulsion system has three SSMEs, each weighing 7,400 lbs and providing 470,000 lbs of thrust at 100% rated power level. To ensure required safety and reliability levels are achieved with the reusable engines, each SSME is partially disassembled, inspected, reassembled, and retested at Kennedy Space Center between each flight. Maintenance processing must be performed very carefully to replace any suspect components, maintain proper engine configuration, and avoid introduction of contaminants that could affect performance and safety. The long service life, and number, complexity, and pedigree of SSME components makes logistics functions extremely critical. One SSME logistics challenge is documenting the assembly and disassembly of the complex joint configurations. This data (joint nomenclature, seal and fastener identification and orientation, assembly sequence, fastener torques, etc.) must be available to technicians and engineers during processing. Various assembly drawings and procedures contain this information, but in this format the required (practical) joint data can be hard to find, due to the continued use of archaic engineering drawings and microfilm for field site use. Additionally, the release system must traverse 2,500 miles between design center and field site, across three time zones, which adds communication challenges and time lags for critical engine configuration data. To aid in information accessibility, a Joint Data List (JDL) was developed that allows efficient access to practical joint data. The published JDL has been a very useful logistics product, providing illustrations and information on the latest SSME configuration. The JDL identifies over 3,350 unique parts across seven fluid systems, over 300 joints, times two distinct engine configurations. The JDL system was recently converted to a web-based, navigable

  12. Space Shuttle Main Engine nozzle mounted optic for throat plane spectroscopy

    NASA Astrophysics Data System (ADS)

    Bickford, R. L.; Duncan, D. B.; Madzsar, G.

    1991-06-01

    A program intended to develop a flight-capable nozzle mounted optic for monitoring emissions from metals entrained in the Space Shuttle Main Engine (SSME) flowfield is described. The optic will collect light emitted from metal atoms within the high-temperature, high-pressure SSME chamber and transfer the optical signal to a high-resolution spectrometer via a fiber-optic cable. The nozzle mounted optic makes it possible to conduct earth-to-orbit monitoring of flowfield emissions without requiring modifications to the SSME.

  13. Combustion Device Failures During Space Shuttle Main Engine Development

    NASA Technical Reports Server (NTRS)

    Goetz, Otto K.; Monk, Jan C.

    2005-01-01

    Major Causes: Limited Initial Materials Properties. Limited Structural Models - especially fatigue. Limited Thermal Models. Limited Aerodynamic Models. Human Errors. Limited Component Test. High Pressure. Complicated Control.

  14. High temperature turbine engine structure

    DOEpatents

    Carruthers, William D.; Boyd, Gary L.

    1993-01-01

    A high temperature ceramic/metallic turbine engine includes a metallic housing which journals a rotor member of the turbine engine. A ceramic disk-like shroud portion of the engine is supported on the metallic housing portion and maintains a close running clearance with the rotor member. A ceramic spacer assembly maintains the close running clearance of the shroud portion and rotor member despite differential thermal movements between the shroud portion and metallic housing portion.

  15. High temperature turbine engine structure

    DOEpatents

    Carruthers, William D.; Boyd, Gary L.

    1992-01-01

    A high temperature ceramic/metallic turbine engine includes a metallic housing which journals a rotor member of the turbine engine. A ceramic disk-like shroud portion of the engine is supported on the metallic housing portion and maintains a close running clearance with the rotor member. A ceramic spacer assembly maintains the close running clearance of the shroud portion and rotor member despite differential thermal movements between the shroud portion and metallic housing portion.

  16. High temperature turbine engine structure

    DOEpatents

    Carruthers, William D.; Boyd, Gary L.

    1994-01-01

    A high temperature ceramic/metallic turbine engine includes a metallic housing which journals a rotor member of the turbine engine. A ceramic disk-like shroud portion of the engine is supported on the metallic housing portion and maintains a close running clearance with the rotor member. A ceramic spacer assembly maintains the close running clearance of the shroud portion and rotor member despite differential thermal movements between the shroud portion and metallic housing portion.

  17. Space Shuttle Main Engine Off-Nominal Low Power Level Operation

    NASA Technical Reports Server (NTRS)

    Bradley, Michael

    1997-01-01

    This paper describes Rocketdyne's successful analysis and demonstration of the Space Shuttle Main Engine (SSME) operation at off-nominal power levels during Reusable Launch Vehicle (RLV) evaluation tests. The nominal power level range for the SSME is from 65% rated power level (RPL) to 109% RPL. Off-nominal power levels incrementally demonstrated were: 17% RPL, 22% RPL, 27% RPL, 40% RPL, 45% RPL, and 50% RPL. Additional achievements during low power operation included: use of a hydrostatic bearing High Pressure Oxidizer Turbopump (HPOTP), nominal High Pressure Fuel Turbopump (HPFTP) first rotor critical speed operation, combustion stability at low power levels, and refined definition of nozzle flow separation heat loads.

  18. Automation based on knowledge modeling theory and its applications in engine diagnostic systems using Space Shuttle Main Engine vibrational data

    NASA Astrophysics Data System (ADS)

    Kim, Jonnathan H.

    1995-04-01

    Humans can perform many complicated tasks without explicit rules. This inherent and advantageous capability becomes a hurdle when a task is to be automated. Modern computers and numerical calculations require explicit rules and discrete numerical values. In order to bridge the gap between human knowledge and automating tools, a knowledge model is proposed. Knowledge modeling techniques are discussed and utilized to automate a labor and time intensive task of detecting anomalous bearing wear patterns in the Space Shuttle Main Engine (SSME) High Pressure Oxygen Turbopump (HPOTP).

  19. Space shuttle main engine anomaly data and inductive knowledge based systems: Automated corporate expertise

    NASA Technical Reports Server (NTRS)

    Modesitt, Kenneth L.

    1987-01-01

    Progress is reported on the development of SCOTTY, an expert knowledge-based system to automate the analysis procedure following test firings of the Space Shuttle Main Engine (SSME). The integration of a large-scale relational data base system, a computer graphics interface for experts and end-user engineers, potential extension of the system to flight engines, application of the system for training of newly-hired engineers, technology transfer to other engines, and the essential qualities of good software engineering practices for building expert knowledge-based systems are among the topics discussed.

  20. Test Results of the Modified Space Shuttle Main Engine at the Marshall Space Flight Center Technology Test Bed Facility

    NASA Technical Reports Server (NTRS)

    Cook, J.; Dumbacher, D.; Ise, M.; Singer, C.

    1990-01-01

    A modified space shuttle main engine (SSME), which primarily includes an enlarged throat main combustion chamber with the acoustic cavities removed and a main injector with the stability control baffles removed, was tested. This one-of-a-kind engine's design changes are being evaluated for potential incorporation in the shuttle flight program in the mid-1990's. Engine testing was initiated on September 15, 1988 and has accumulated 1,915 seconds and 19 starts. Testing is being conducted to characterize the engine system performance, combustion stability with the baffle-less injector, and both low pressure oxidizer turbopump (LPOTP) and high pressure oxidizer turbopump (HPOTP) for suction performance. These test results are summarized and compared with the SSME flight configuration data base. Testing of this new generation SSME is the first product from the technology test bed (TTB). Figure test plans for the TTB include the highly instrumented flight configuration SSME and advanced liquid propulsion technology items.

  1. Low loss injector for Space Shuttle main engine. Center director's discretionary fund

    NASA Technical Reports Server (NTRS)

    Vonpragenau, G. L.

    1984-01-01

    An efficient propellant injection method to raise the Space Shuttle Main Engine (SSME) thrust and payload is discussed. Relatively large diameter injector elements with low pressure loss are recommended for the main combustion chamber and the pre-burners. Smaller losses admit more propellant flow which then raises thrust. Payload is not only gained by specific impulse but also by thrust. The chamber pressure is stabilized by selecting the proper cavity size for the injector elements while reducing the injection pressure loss which normally is kept high for stability. The rather large injector element recesses provide acoustic damping which makes baffles and acoustic absorbers unnecessary. A tenfold reduction of flow induced stresses which are rather high in the present design is shown. Relaxed tolerances, fewer elements, and better maintenance are offered. The study was conducted under a center director discretionary fund assignment.

  2. Airflow Model Testing to Determine the Distribution of Hot Gas Flow and O/F Ratio Across the Space Shuttle Main Engine Main Injector Assembly

    NASA Technical Reports Server (NTRS)

    Mahorter, L.; Chik, J.; McDaniels, D.; Dill, C.

    1990-01-01

    Engine 0209, the certification engine for the new Phase 2+ Hot Gas Manifold (HGM), showed severe deterioration of the Main Combustion Chamber (MCC) liner during hot fire tests. One theory on the cause of the damage held that uneven local distribution of the fuel rich hot gas flow through the main injector assembly was producing regions of high oxidizer/fuel (O/F) ratio near the wall of the MCC liner. Airflow testing was proposed to measure the local hot gas flow rates through individual injector elements. The airflow tests were conducted using full scale, geometrically correct models of both the current Phase 2 and the new Phase 2+ HGMs. Different main injector flow shield configurations were tested for each HGM to ascertain their effect on the pressure levels and distribution of hot gas flow. Instrumentation located on the primary faceplate of the main injector measured hot gas flow through selected injector elements. These data were combined with information from the current space shuttle main engine (SSME) power balances to produce maps of pressure, hot gas flow rate, and O/F ratio near the main injector primary plate. The O/F distributions were compared for the different injector and HGM configurations.

  3. Steady-state analysis of a nonlinear rotor-housing system. [Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Noah, S. T.; Kim, Y. B.

    1990-01-01

    The periodic steady state response of a high pressure oxygen turbopump (HBOTP) of a Space Shuttle main engine (SSME), involving a clearance between the bearing and housing carrier, is sought. A harmonic balance method utilizig Fast Fourier Transform (FFT) algorithm is developed for the analysis. An impedance method is used to reduce the number of degrees of freedom to the displacements at the bearing clearance. Harmonic and subharmonic responses to imbalance for various system parameters are studied. The results show that the computational technique developed in this study is an effective and flexible method for determining the stable and unstable periodic response of complex rotor-housing systems with clearance type nonlinearity.

  4. High-Temperature Rocket Engine

    NASA Technical Reports Server (NTRS)

    Schneider, Steven J.; Rosenberg, Sanders D.; Chazen, Melvin L.

    1994-01-01

    Two rocket engines that operate at temperature of 2,500 K designed to provide thrust for station-keeping adjustments of geosynchronous satellites, for raising and lowering orbits, and for changing orbital planes. Also useful as final propulsion stages of launch vehicles delivering small satellites to low orbits around Earth. With further development, engines used on planetary exploration missions for orbital maneuvers. High-temperature technology of engines adaptable to gas-turbine combustors, ramjets, scramjets, and hot components of many energy-conversion systems.

  5. Enabling High Efficiency Ethanol Engines

    SciTech Connect

    Szybist, J.; Confer, K.

    2011-03-01

    Delphi Automotive Systems and ORNL established this CRADA to explore the potential to improve the energy efficiency of spark-ignited engines operating on ethanol-gasoline blends. By taking advantage of the fuel properties of ethanol, such as high compression ratio and high latent heat of vaporization, it is possible to increase efficiency with ethanol blends. Increasing the efficiency with ethanol-containing blends aims to remove a market barrier of reduced fuel economy with E85 fuel blends, which is currently about 30% lower than with petroleum-derived gasoline. The same or higher engine efficiency is achieved with E85, and the reduction in fuel economy is due to the lower energy density of E85. By making ethanol-blends more efficient, the fuel economy gap between gasoline and E85 can be reduced. In the partnership between Delphi and ORNL, each organization brought a unique and complementary set of skills to the project. Delphi has extensive knowledge and experience in powertrain components and subsystems as well as overcoming real-world implementation barriers. ORNL has extensive knowledge and expertise in non-traditional fuels and improving engine system efficiency for the next generation of internal combustion engines. Partnering to combine these knowledge bases was essential towards making progress to reducing the fuel economy gap between gasoline and E85. ORNL and Delphi maintained strong collaboration throughout the project. Meetings were held regularly, usually on a bi-weekly basis, with additional reports, presentations, and meetings as necessary to maintain progress. Delphi provided substantial hardware support to the project by providing components for the single-cylinder engine experiments, engineering support for hardware modifications, guidance for operational strategies on engine research, and hardware support by providing a flexible multi-cylinder engine to be used for optimizing engine efficiency with ethanol-containing fuels.

  6. High Stability Engine Control (HISTEC)

    NASA Technical Reports Server (NTRS)

    DeLaat, John C.; Southwick, Robert D.; Gallops, George W.

    1996-01-01

    Future aircraft turbine engines, both commercial and military, must be able to successfully accommodate expected increased levels of steady-state and dynamic engine-face distortion. The current approach of incorporating a sufficient component design stall margin to tolerate these increased levels of distortion would significantly reduce performance. The objective of the High Stability Engine Control (HISTEC) program is to design, develop, and flight demonstrate an advanced, high-stability, integrated engine control system that uses measurement-based, real-time estimates of distortion to enhance engine stability. The resulting distortion tolerant control reduces the required design stall margin, with a corresponding increase in performance and decrease in fuel burn. The HISTEC concept, consisting of a Distortion Estimation System and a Stability Management Control, has been designed and developed. The Distortion Estimation System uses a small number of high-response pressure sensors at the engine face to calculate indicators of the type and extent of distortion in real time. The Stability Management Control, through direct control of the fan and compressor pressure ratio, accommodates the distortion by transiently increasing the amount of stall margin available based on information from the Distortion Estimation System. Simulation studies have shown the HISTEC distortion tolerant control is able to successfully estimate and accommodate time-varying distortion. Currently, hardware and software systems necessary for flight demonstration of the HISTEC concept are being designed and developed. The HISTEC concept will be flight tested in early 1997.

  7. History of Space Shuttle Main Engine Turbopump Bearing Testing at the Marshall Space Flight Center

    NASA Technical Reports Server (NTRS)

    Gibson, Howard; Thom, Robert; Moore, Chip; Haluck, Dave

    2010-01-01

    The Space Shuttle is propelled into orbit by two solid rocket motors and three liquid fed main engines. After the solid motors fall away, the shuttle engines continue to run for a total time of 8 minutes. These engines are fed propellants by low and high pressure turbopumps. A critical part of the turbopump is the main shaft that supports the drive turbine and the pump inducer and impeller. Rolling element bearings hold the shaft in place during rotation. If the bearings were to fail, the shaft would move, allowing components to rub in a liquid oxygen or hydrogen environment, which could have catastrophic results. These bearings are required to spin at very high speeds, support radial and axial loads, and have high wear resistance without the benefit of a conventional means of lubrication. The Rocketdyne built Shuttle turbopumps demonstrated their capability to perform during launches; however, the seven hour life requirement was not being met. One of the limiting factors was the bearings. In the late 1970's, an engineering team was formed at the Marshall Space Flight Center (MSFC), to develop a test rig and plan for testing the Shuttle s main engine high pressure oxygen turbopump (HPOTP) bearings. The goals of the program were to better understand the operation of bearings in a cryogenic environment and to further develop and refine existing computer models used to predict the operational limits of these bearings. In 1982, testing began in a rig named the Bearing and Seal Material Tester or BSMT as it was commonly called. The first testing investigated the thermal margin and thermal runaway limits of the HPOTP bearings. The test rig was later used to explore potential bearing improvements in the area of increased race curvatures, new cage materials for better lubrication, new wear resistant rolling element materials, and other ideas to improve wear life. The most notable improvements during this tester s time was the incorporation of silicon nitride balls and

  8. Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

    NASA Technical Reports Server (NTRS)

    Holmes, Richard R.; Elam, Sandra K.; McKechnie, Timothy N.; Power, Christopher A.

    2010-01-01

    In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

  9. Pressurized high frequency thermoacoustic engines

    NASA Astrophysics Data System (ADS)

    Webb, Nicholas D.

    Acoustic heat engines show much promise for converting waste heat to electricity. Since most applications require high power levels, high frequency thermoacoustic engines can reach such performance by operating with a pressurized working gas. Results on a 3 kHz prime mover, consisting of a quarter-wave resonator and a random stack material between two heat exchangers, show that the acoustic power from such a device is raised substantially as the working gas is pressurized. At pressures up to approximately 10 bar, the increase in acoustic power is approximately linear to the increase in pressure, and thus is an effective way to increase the power output of thermoacoustic engines. Since the heat input was not changed during the experiments, the increases in acoustic power translate directly to increases in engine efficiency which is calculated as the output acoustic power divided by the input heat power. In most experiments run in this study, the engine efficiency increased by a factor of at least 4 as the pressure was increased from 2 bar up to about 10 bar. Further increases in pressure lead to acoustic power saturation and eventual attenuation. This is most likely due to a combination of several factors including the shrinking thermal penetration depth, and the fact that the losses increase faster with pressure in a random stack material than in traditional parallel plates. Pressurization also leads to a lower DeltaT for onset of oscillations in the range of 10 bar of mean pressure, potentially opening up even more heat sources that can power a thermoacoustic engine. Results from another 3 kHz engine, one that was pressurized itself as opposed to being placed in a pressurized chamber, are also presented. The configuration of this engine solves the problem of how to simultaneously pressurize the engine and inject heat into the hot heat exchanger. It was also noted that the geometry of the resonator cavity in the quarter wavelength pressurized engine plays an

  10. Leak Location and Classification in the Space Shuttle Main Engine Nozzle by Infrared Testing

    NASA Technical Reports Server (NTRS)

    Russell, Samuel S.; Walker, James L.; Lansing, Mathew

    2003-01-01

    The Space Shuttle Main Engine (SSME) is composed of cooling tubes brazed to the inside of a conical structural jacket. Because of the geometry there are regions that can't be inspected for leaks using the bubble solution and low-pressure method. The temperature change due escaping gas is detectable on the surface of the nozzle under the correct conditions. The methods and results presented in this summary address the thermographic identification of leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute temperature change associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

  11. Real-time control for manufacturing space shuttle main engines: Work in progress

    NASA Technical Reports Server (NTRS)

    Ruokangas, Corinne C.

    1988-01-01

    During the manufacture of space-based assemblies such as Space Shuttle Main Engines, flexibility is required due to the high-cost and low-volume nature of the end products. Various systems have been developed pursuing the goal of adaptive, flexible manufacturing for several space applications, including an Advanced Robotic Welding System for the manufacture of complex components of the Space Shuttle Main Engines. The Advanced Robotic Welding System (AROWS) is an on-going joint effort, funded by NASA, between NASA/Marshall Space Flight Center, and two divisions of Rockwell International: Rocketdyne and the Science Center. AROWS includes two levels of flexible control of both motion and process parameters: Off-line programming using both geometric and weld-process data bases, and real-time control incorporating multiple sensors during weld execution. Both control systems were implemented using conventional hardware and software architectures. The feasibility of enhancing the real-time control system using the problem-solving architecture of Schemer is investigated and described.

  12. High School Teachers' Conceptions of Engineers and Engineering

    ERIC Educational Resources Information Center

    Hoh, Yin Kiong

    2012-01-01

    This paper describes a workshop activity the author has carried out with 80 high school science teachers to enable them to overcome their stereotypical perceptions of engineers and engineering. The activity introduced them to the biographies of prominent women in engineering, and raised their awareness of these female engineers' contributions to…

  13. High temperature turbine engine structure

    DOEpatents

    Boyd, Gary L.

    1991-01-01

    A high temperature turbine engine includes a rotor portion having axially stacked adjacent ceramic rotor parts. A ceramic/ceramic joint structure transmits torque between the rotor parts while maintaining coaxial alignment and axially spaced mutually parallel relation thereof despite thermal and centrifugal cycling.

  14. High temperature turbine engine structure

    DOEpatents

    Boyd, Gary L.

    1990-01-01

    A high temperature turbine engine includes a hybrid ceramic/metallic rotor member having ceramic/metal joint structure. The disclosed joint is able to endure higher temperatures than previously possible, and aids in controlling heat transfer in the rotor member.

  15. Configuration evaluation and criteria plan. Volume 2: Evaluation criteria plan (update). Space Transportation Main Engine (STME) configuration study

    NASA Technical Reports Server (NTRS)

    Bair, E. K.

    1987-01-01

    Candidate main engine configurations which enhance vehicle performance, operation and cost are identified. These candidate configurations are evaluated and the configurations which provide significant advantages over existing systems are selected for consideration for the next generation of launch vehicles. The unbiased selection of the Space Transportation Main Engine (STME) configuration requires that the candidate engines be evaluated against a predetermined set of criteria which must be properly weighted to emphasize critical requirements defined prior to the actual evaluation. During a prior study of the STME a Gas Generator Cycle engine was selected for conceptual design, with emphasis on reusability, reliability and low cost while achieving good performance. In this study emphasis is on expendable application of the STME while maintaining low cost and high reliability.

  16. Emissions of NOx, particle mass and particle numbers from aircraft main engines, APU's and handling equipment at Copenhagen Airport

    NASA Astrophysics Data System (ADS)

    Winther, Morten; Kousgaard, Uffe; Ellermann, Thomas; Massling, Andreas; Nøjgaard, Jacob Klenø; Ketzel, Matthias

    2015-01-01

    This paper presents a detailed emission inventory for NOx, particle mass (PM) and particle numbers (PN) for aircraft main engines, APU's and handling equipment at Copenhagen Airport (CPH) based on time specific activity data and representative emission factors for the airport. The inventory has a high spatial resolution of 5 m × 5 m in order to be suited for further air quality dispersion calculations. Results are shown for the entire airport and for a section of the airport apron area ("inner apron") in focus. The methodology presented in this paper can be used to quantify the emissions from aircraft main engines, APU and handling equipment in other airports. For the entire airport, aircraft main engines is the largest source of fuel consumption (93%), NOx, (87%), PM (61%) and PN (95%). The calculated fuel consumption [NOx, PM, PN] shares for APU's and handling equipment are 5% [4%, 8%, 5%] and 2% [9%, 31%, 0%], respectively. At the inner apron area for handling equipment the share of fuel consumption [NOx, PM, PN] are 24% [63%, 75%, 2%], whereas APU and main engines shares are 43% [25%, 19%, 54%], and 33% [11%, 6%, 43%], respectively. The inner apron NOx and PM emission levels are high for handling equipment due to high emission factors for the diesel fuelled handling equipment and small for aircraft main engines due to small idle-power emission factors. Handling equipment is however a small PN source due to the low number based emission factors. Jet fuel sulphur-PM sensitivity calculations made in this study with the ICAO FOA3.0 method suggest that more than half of the PM emissions from aircraft main engines at CPH originate from the sulphur content of the fuel used at the airport. Aircraft main engine PN emissions are very sensitive to the underlying assumptions. Replacing this study's literature based average emission factors with "high" and "low" emission factors from the literature, the aircraft main engine PN emissions were estimated to change with a

  17. Detection, Location, and Classification of Space Shuttle Main Engine Nozzle Leaks by Transient Thermographic Inspection

    NASA Technical Reports Server (NTRS)

    Russell, Samuel S.; Walker, James L.

    1998-01-01

    Leak checking and evaluation of pressure vessels by observing the slight temperature changes resulting from structural anomalies has been made possible through developments in high resolution infrared cameras and advanced image processing. These developments have made thermal nondestructive analysis a very practical and efficient method to determine material consistency and structural quality as well as monitor processes. The Space Shuttle Main Engine Nozzle has regions which can not be inspected with standard leak check methods. The Thermographic methods being developed to nondestructively test the Nozzle for leaks in inaccessible regions are reported. Also, a flash heating Thermographic investigation of the braze line bonding the cooling tubes to the outer structural jacket of the nozzle is reported.

  18. Thermal Analysis on Plume Heating of the Main Engine on the Crew Exploration Vehicle Service Module

    NASA Technical Reports Server (NTRS)

    Wang, Xiao-Yen J.; Yuko, James R.

    2007-01-01

    The crew exploration vehicle (CEV) service module (SM) main engine plume heating is analyzed using multiple numerical tools. The chemical equilibrium compositions and applications (CEA) code is used to compute the flow field inside the engine nozzle. The plume expansion into ambient atmosphere is simulated using an axisymmetric space-time conservation element and solution element (CE/SE) Euler code, a computational fluid dynamics (CFD) software. The thermal analysis including both convection and radiation heat transfers from the hot gas inside the engine nozzle and gas radiation from the plume is performed using Thermal Desktop. Three SM configurations, Lockheed Martin (LM) designed 604, 605, and 606 configurations, are considered. Design of multilayer insulation (MLI) for the stowed solar arrays, which is subject to plume heating from the main engine, among the passive thermal control system (PTCS), are proposed and validated.

  19. Sloshing in the Liquid Hydrogen and Liquid Oxygen Propellant Tanks After Main Engine Cut Off

    NASA Technical Reports Server (NTRS)

    Kim, Sura; West, Jeff

    2011-01-01

    NASA Marshall Space Flight Center is designing and developing the Main Propulsion System (MPS) for Ares launch vehicles. Propellant sloshing in the liquid hydrogen (LH2) and liquid oxygen (LO2) propellant tanks after Main Engine Cut Off (MECO) was modeled using the Volume of Fluid (VOF) module of the computational fluid dynamics code, CFD-ACE+. The present simulation shows that there is substantial sloshing side forces acting on the LH2 tank during the deceleration of the vehicle after MECO. The LH2 tank features a side wall drain pipe. The side loads result from the residual propellant mass motion in the LH2 tank which is initiated by the stop of flow into the drain pipe at MECO. The simulations show that radial force on the LH2 tank wall is less than 50 lbf and the radial moment calculated based up through the center of gravity of the vehicle is predicted to be as high as 300 lbf-ft. The LO2 tank features a bottom dome drain system and is equipped with sloshing baffles. The remaining LO2 in the tank slowly forms a liquid column along the centerline of tank under the zero gravity environments. The radial force on the LO2 tank wall is predicted to be less than 100 lbf. The radial moment calculated based on the center of gravity of the vehicle is predicted as high as 4500 lbf-ft just before MECO and dropped down to near zero after propellant draining stopped completely.

  20. The Development of Titanium Alloys for Application in the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Halchak, John A.; Jerman, Gregory A.; Zimmerman, Frank R.

    2010-01-01

    The high-strength-to-weight ratio of titanium alloys, particularly at cryogenic temperatures, make them attractive for application in rocket engines - offering the potential of superior performance while minimizing component weight. This was particularly attractive for rotating components, such as pump impellers, where titanium alloys presented the potential to achieve a major advance in rotational tip speed, with a reduction in stages and resultant saving in pump weight and complexity. The investigation into titanium alloys for application in cryogenic turbopumps began in the early 1960's. However, it was found that the reactivity of titanium limited applications and produced unique processing challenges. Specialized chemical compositions and processing techniques had to be developed. A substantial amount of material properties testing and trials in experimental turbopumps occurred, ultimately leading to application in the Space Shuttle Main Engine. One particular alloy stood out for use at liquid hydrogen temperatures, Ti-5Al-2.5Sn ELI. This alloy was employed for several critical components. This presentation deals with the development effort, the challenges that were encountered and operational experiences with Ti-5Al-2.5Sn ELI in the SSME.

  1. Understanding the Space Shuttle Main Engine Hydraulic Actuation System and Reviewing Its Evolution

    NASA Technical Reports Server (NTRS)

    McWade, Robert J.; Minor, Robert B.; McNutt, Leslie M.

    2010-01-01

    The complex engine start and thrust control requirements of the Space Shuttle Main Engine (SSME) require unique valve, actuator and control system hardware. The Hydraulic Actuation System (HAS) was designed, developed, and now operates to meet tight engine control requirement limits to assure safe, reliable and correct engine thrust at all times. The actuator is designed to be fail safe and fail operate in the areas where redundancy is important. The HAS has an additional pneumatic operating capability that insures a safe sequential closure of all actuators and propellant valves in the event of the loss of hydraulic system pressure or loss of electrical closed loop control of the actuator. The objective of this paper is to provide a complete description of the actuator s internal operating system, along with its interaction with all SSME system interfaces. Additionally the paper addresses the challenges, problems identified, and corrected, and lessons learned, during the course of the almost 35 years of engine operation.

  2. Space Shuttle Main Engine fuel preburner augmented spark igniter shutdown detonations

    NASA Technical Reports Server (NTRS)

    Dexter, C. E.; Mccay, T. D.

    1986-01-01

    Detonations were experienced in the Space Shuttle Main Engine fuel preburner (FPB) augmented spark igniter (ASI) during engine cutoff. Several of these resulted in over pressures sufficient to damage the FPB ASI oxidizer system. The detonations initiated in the FPB ASI oxidizer line when residual oxidizer (oxygen) in the line mixed with backflowing fuel (hydrogen) and detonated. This paper reviews the damage history to the FPB ASI oxidizer system, an engineering assessment of the problem cause, a verification of the mechanisms, the hazards associated with the detonations, and the solution implemented.

  3. An overview of the current technology relevant to the design and development of the Space Transportation Main Engine (STME)

    NASA Technical Reports Server (NTRS)

    Das, Digendra K.

    1991-01-01

    The objective of this project was to review the latest literature relevant to the Space Transportation Main Engine (STME). The search was focused on the following engine components: (1) gas generator; (2) hydrostatic/fluid bearings; (3) seals/clearances; (4) heat exchanges; (5) nozzles; (6) nozzle/main combustion chamber joint; (7) main injector face plate; and (8) rocket engine.

  4. Factors influencing design and selection of GTAW robotic welding machines for the Space Shuttle main engine

    NASA Technical Reports Server (NTRS)

    Flanigan, L.

    1986-01-01

    Proposed hardware and software for microprocessor-controlled power supplies and welding machines are described. The application of the automatic seven-axis welding machine, which is to be preprogrammed to allow minimum intervention by the welding operator during the actual process, to the welding of the Space Shuttle main engine is discussed. The production requirements for the gas tungsten arc welds for the Space Shuttle main engine are examined. Consideration is given to positioner design, welding variables, inert shielding gas management, filler metal wire control, the up loading and down loading of data from off-line computers, process improvements, tooling, the welding variable library, and adaptive sensor control.

  5. Space shuttle main engine definition (phase B). Volume 2: Avionics. [for space shuttle

    NASA Technical Reports Server (NTRS)

    1971-01-01

    The advent of the space shuttle engine with its requirements for high specific impulse, long life, and low cost have dictated a combustion cycle and a closed loop control system to allow the engine components to run close to operating limits. These performance requirements, combined with the necessity for low operational costs, have placed new demands on rocket engine control, system checkout, and diagnosis technology. Based on considerations of precision environment, and compatibility with vehicle interface commands, an electronic control, makes available many functions that logically provide the information required for engine system checkout and diagnosis.

  6. Fluid mass and thermal loading effects on the modal characteristics of space shuttle main engine liquid oxygen inlet splitter vanes

    NASA Technical Reports Server (NTRS)

    Panossian, H. V.; Boehnlein, J. J.

    1987-01-01

    An analysis and evaluation of experimental modal survey test data on the variations of modal characteristics induced by pressure and thermal loading events are presented. Extensive modal survey tests were carried out on a Space Shuttle Main Engine (SSME) test article using liquid nitrogen under cryogenic temperatures and high pressures. The results suggest that an increase of pressure under constant cryogenic temperature or a decrease of temperature under high pressure induces an upward shift of frequencies of various modes of the structures.

  7. High School Engineering: Pre-Engineering for Future Engineers.

    ERIC Educational Resources Information Center

    Sutter, Gary R.

    1998-01-01

    Describes a course that bridges the gap between pure science and pure technology called Pre-Engineering. This course gives junior and senior students a chance to investigate the possibility of choosing engineering as a major in college as well as to experience hands-on activities, projects, laboratories, problem solving, and computer simulations…

  8. Apollo-11 25th Arniversary celebration: Space Shuttle Main Engine - Technology Test Bed (SSME-TTB)

    NASA Technical Reports Server (NTRS)

    1994-01-01

    On the 25th Anniversary of the Apollo-11 space launch, Marshall celebrated with a test firing of the Space Shuttle Main Engine at the Technology Test Bed (SSME-TTB). This drew a large crowd who stood in the fields around the test site and watched as plumes of white smoke verified ignition.

  9. Research pressure instrumentation for NASA Space Shuttle main engine, modification no. 5

    NASA Technical Reports Server (NTRS)

    Anderson, P. J.; Nussbaum, P.; Gustafson, G.

    1984-01-01

    Research concerning the development of pressure instrumentation for the space shuttle main engine is reported. The following specific topics were addressed: (1) transducer design and materials, (2) silicon piezoresistor characterization at cryogenic temperatures, (3) chip mounting characterization, and (4) frequency response optimization.

  10. STS-26 space shuttle main engine (SSME) tested by technicians at NSTL

    NASA Technical Reports Server (NTRS)

    1988-01-01

    Technicians use electronic equipment to run final tests on STS-26 space shuttle main engine (SSME) at National Space Technology Laboratory before shipping it to Kennedy Space Center (KSC) for installation in Discovery, Orbiter Vehicle (OV) 103. Red protective cover is secured over SSME nozzle.

  11. Alpha-canonical form representation of the open loop dynamics of the Space Shuttle main engine

    NASA Technical Reports Server (NTRS)

    Duyar, Almet; Eldem, Vasfi; Merrill, Walter C.; Guo, Ten-Huei

    1991-01-01

    A parameter and structure estimation technique for multivariable systems is used to obtain a state space representation of open loop dynamics of the space shuttle main engine in alpha-canonical form. The parameterization being used is both minimal and unique. The simplified linear model may be used for fault detection studies and control system design and development.

  12. Quiet Clean Short-haul Experimental Engine (QCSEE) main reduction gears detailed design report

    NASA Technical Reports Server (NTRS)

    Defeo, A.; Kulina, M.

    1977-01-01

    Lightweight turbine engines with geared slower speed fans are considered. The design of two similar but different gear ratio, minimum weight, epicyclic star configuration main reduction gears for the under the wing (UTW) and over the wing (OTW) engines is discussed. The UTW engine reduction gear has a ratio of 2.465:1 and a 100% power design rating of 9885 kW (13,256 hp) at 3143 rpm fan speed. The OTW engine reduction gear has a ratio of 2.062:1 and a 100% power design rating of 12813 kW (17183 hp) at 3861 rpm fan speed. Details of configuration, stresses, deflections, and lubrication are presented.

  13. Inductive knowledge acquisition experience with commercial tools for space shuttle main engine testing

    NASA Technical Reports Server (NTRS)

    Modesitt, Kenneth L.

    1990-01-01

    Since 1984, an effort has been underway at Rocketdyne, manufacturer of the Space Shuttle Main Engine (SSME), to automate much of the analysis procedure conducted after engine test firings. Previously published articles at national and international conferences have contained the context of and justification for this effort. Here, progress is reported in building the full system, including the extensions of integrating large databases with the system, known as Scotty. Inductive knowledge acquisition has proven itself to be a key factor in the success of Scotty. The combination of a powerful inductive expert system building tool (ExTran), a relational data base management system (Reliance), and software engineering principles and Computer-Assisted Software Engineering (CASE) tools makes for a practical, useful and state-of-the-art application of an expert system.

  14. A data base and analysis program for shuttle main engine dynamic pressure measurements

    NASA Technical Reports Server (NTRS)

    Coffin, T.

    1986-01-01

    A dynamic pressure data base management system is described for measurements obtained from space shuttle main engine (SSME) hot firing tests. The data were provided in terms of engine power level and rms pressure time histories, and power spectra of the dynamic pressure measurements at selected times during each test. Test measurements and engine locations are defined along with a discussion of data acquisition and reduction procedures. A description of the data base management analysis system is provided and subroutines developed for obtaining selected measurement means, variances, ranges and other statistics of interest are discussed. A summary of pressure spectra obtained at SSME rated power level is provided for reference. Application of the singular value decomposition technique to spectrum interpolation is discussed and isoplots of interpolated spectra are presented to indicate measurement trends with engine power level. Program listings of the data base management and spectrum interpolation software are given. Appendices are included to document all data base measurements.

  15. Space shuttle main engine sensor modeling using radial-basis-function neural networks

    NASA Astrophysics Data System (ADS)

    Wheeler, Kevin R.; Dhawan, Atam P.; Meyer, Claudia M.

    1994-11-01

    An efficient method of parameter prediction is needed for sensor validation of space shuttle main-engine (SSME) parameters during real-time safety monitoring and post-test analysis. Feedforward neural networks (FFNN) have been used to model the highly nonlinear and dynamic SSME parameters during startup. Due to several problems associated with the use of feedforward networks, radial-basis-function neural networks (RBFNN) were investigated in modeling SSME parameters. In this paper, RBFNNs are used to predict the high-pressure oxidizer turbine discharge temperature, a redlined parameter, during the startup transient. Data from SSME ground test firings were used to train and validate the RBFNNs. The performance of the RBFNN model is compared with that of a FFNN model, trained with the Quickprop learning algorithm. In comparison with the FFNN model, the RBFNN-based model was found to be more robust against variations in architecture and network parameters, and was faster to train. In addition, the performance of the RBFNN model during nominal operation and during simulated input sensor failures was found to be robust in the presence of small deviations in the input.

  16. CARS temperature measurements in the fuel preburner of the Space Shuttle main engine: A feasibility study

    NASA Technical Reports Server (NTRS)

    Beiting, E. J.; Luthe, J. C.

    1983-01-01

    This report discusses the feasibility of making temperature profile measurements in the fuel preburner of the main engine of the space shuttle (SSME) using coherent anti-Stokes Raman spectroscopy (CARS). The principal thrust of the work is to identify problems associated with making CARS measurements in high temperature gas phase hydrogen at very high pressures (approx 400 atmospheres). To this end a theoretical study was made of the characteristics of the CAR spectra of H2 as a function of temperature and pressure and the accuracy with which temperatures can be extracted from this spectra. In addition the experimental problems associated with carrying out these measurements on a SSME at NSTL were identified. A conceptual design of a CARS system suitable for this work is included. Many of the results of the calculations made in this report are plotted as a function of temperature. In the course of presenting these results, it was necessary to decide whether the number of density or the pressure should be treated as a fixed parameter.

  17. High-Performance Bipropellant Engine

    NASA Technical Reports Server (NTRS)

    Biaglow, James A.; Schneider, Steven J.

    1999-01-01

    TRW, under contract to the NASA Lewis Research Center, has successfully completed over 10 000 sec of testing of a rhenium thrust chamber manufactured via a new-generation powder metallurgy. High performance was achieved for two different propellants, N2O4- N2H4 and N2O4 -MMH. TRW conducted 44 tests with N2O4-N2H4, accumulating 5230 sec of operating time with maximum burn times of 600 sec and a specific impulse Isp of 333 sec. Seventeen tests were conducted with N2O4-MMH for an additional 4789 sec and a maximum Isp of 324 sec, with a maximum firing duration of 700 sec. Together, the 61 tests totalled 10 019 sec of operating time, with the chamber remaining in excellent condition. Of these tests, 11 lasted 600 to 700 sec. The performance of radiation-cooled rocket engines is limited by their operating temperature. For the past two to three decades, the majority of radiation-cooled rockets were composed of a high-temperature niobium alloy (C103) with a disilicide oxide coating (R512) for oxidation resistance. The R512 coating practically limits the operating temperature to 1370 C. For the Earth-storable bipropellants commonly used in satellite and spacecraft propulsion systems, a significant amount of fuel film cooling is needed. The large film-cooling requirement extracts a large penalty in performance from incomplete mixing and combustion. A material system with a higher temperature capability has been matured to the point where engines are being readied for flight, particularly the 100-lb-thrust class engine. This system has powder rhenium (Re) as a substrate material with an iridium (Ir) oxidation-resistant coating. Again, the operating temperature is limited by the coating; however, Ir is capable of long-life operation at 2200 C. For Earth-storable bipropellants, this allows for the virtual elimination of fuel film cooling (some film cooling is used for thermal control of the head end). This has resulted in significant increases in specific impulse performance

  18. Italian High-speed Airplane Engines

    NASA Technical Reports Server (NTRS)

    Bona, C F

    1940-01-01

    This paper presents an account of Italian high-speed engine designs. The tests were performed on the Fiat AS6 engine, and all components of that engine are discussed from cylinders to superchargers as well as the test set-up. The results of the bench tests are given along with the performance of the engines in various races.

  19. Sloshing in Liquid Hydrogen and LOX Propellant Tanks After Main Engine Cut-off

    NASA Technical Reports Server (NTRS)

    Kim, Sura

    2011-01-01

    NASA Marshall Space Flight Center is designing and developing the Main Propulsion System (MPS) for Ares launch vehicles. The objective of this study is to calculate the sloshing forces and moments in the LH2 and LO2 propellant tanks using a CFD/VOF analysis under realistic flight conditions. Propellant sloshing in the liquid hydrogen (LH2) and the liquid oxygen (LO2) propellant tanks after Main Engine Cut Off (MECO) was modeled using the Volume of Fluid (VOF) module of the computational fluid dynamics code, CFD-ACE+. The present simulation shows that there are substantial sloshing side forces acting on the LH2 tank during the deceleration of the vehicle after MECO. The LH2 tank features a side wall drain pipe. The side loads result from the residual propellant mass motion in the LH2 tank which is initiated by the stop of flow into the drain pipe at MECO. The simulations show that radial force on the LH2 tank wall is less than 50 lbf and the radial moment calculated based up the center of gravity of the vehicle is predicted to be as high as 300 lbf-ft. The LO2 tank features a bottom dome drain system and is equipped with sloshing baffles. The remaining LO2 in the tank slowly forms a liquid column along the centerline of tank under the zero gravity environments. The radial force on the LO2 tank wall is predicted less than 100 lbf. The radial moment calculated based on the center of gravity of the vehicle is predicted as high as 4500 lbf-ft just before MECO and dropped down to near zero after propellant draining stopped completely.

  20. Binary interactions with high accretion rates onto main sequence stars

    NASA Astrophysics Data System (ADS)

    Shiber, Sagiv; Schreier, Ron; Soker, Noam

    2016-07-01

    Energetic outflows from main sequence stars accreting mass at very high rates might account for the powering of some eruptive objects, such as merging main sequence stars, major eruptions of luminous blue variables, e.g., the Great Eruption of Eta Carinae, and other intermediate luminosity optical transients (ILOTs; red novae; red transients). These powerful outflows could potentially also supply the extra energy required in the common envelope process and in the grazing envelope evolution of binary systems. We propose that a massive outflow/jets mediated by magnetic fields might remove energy and angular momentum from the accretion disk to allow such high accretion rate flows. By examining the possible activity of the magnetic fields of accretion disks, we conclude that indeed main sequence stars might accrete mass at very high rates, up to ≈ 10‑2 M ⊙ yr‑1 for solar type stars, and up to ≈ 1 M ⊙ yr‑1 for very massive stars. We speculate that magnetic fields amplified in such extreme conditions might lead to the formation of massive bipolar outflows that can remove most of the disk's energy and angular momentum. It is this energy and angular momentum removal that allows the very high mass accretion rate onto main sequence stars.

  1. Space Shuttle Main Engine Start with Off-Nominal Propellant Inlet Pressures

    NASA Technical Reports Server (NTRS)

    Bradley, Michael

    1997-01-01

    This paper describes Rocketdyne's successful analysis and demonstration of the Space Shuttle Main Engine (SSME) operation at off-nominal propellant inlet conditions during the Reusable Launch Vehicle (RLV) evaluation tests. The nominal inlet condition range is: 103 to 111 psia and 170.5 to 178 deg. R for the oxidizer and 43 to 47 psia and 37 to 40 deg. R for the fuel. The SSME start was successfully demonstrated with engine inlet pressures of 50 psia liquid oxygen (LOX) with subcooled LOX at 160 deg R and 38 psia fuel at 38 deg. R. Four tests were used to incrementally modify the start sequence to demonstrate the final goal.

  2. Numerical simulation methods of incompressible flows and an application to the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Chang, J. L. C.; Kwak, D.; Rogers, S. E.; Yang, R.-J.

    1988-01-01

    Incompressible Navier-Stokes solution methods are discussed with an emphasis on the pseudocompressibility method. A steady-state flow solver based on the pseudocompressibility approach is then described. This flow-solver code was used to analyze the internal flow in the Space Shuttle main engine hot-gas manifold. Salient features associated with this three-dimensional realistic flow simulation are discussed. Numerical solutions relevant to the current engine analysis and the redesign effort are discussed along with experimental results. This example demonstrates the potential of computational fluid dynamics as a design tool for aerospace applications.

  3. Preliminary analysis of selected gas dynamic problems. [space shuttle main engine main combustion transients and IUS nozzle flow

    NASA Technical Reports Server (NTRS)

    Prozan, R. J.; Farmer, R. C.

    1985-01-01

    The VAST computer code was used to analyze SSME main combustion chamber start-up transients and the IUS flow field for a damaged nozzle was investigated to better understand the gas dynamic considerations involved in vehicle problems, the effect of start transients on the nozzle flow field for the SSME, and the possibility that a damaged nozzle could account for the acceleration anomaly noted on IUS burn. The results obtained were compared with a method of characteristics prediction. Pressure solutions from both codes were in very good agreement and the Mach number solution on the nozzle centerline deviates substantially for the high expansions for the SSME. Since this deviation was unexpected, the phenomenon is being further examined.

  4. Calculation of flow about posts and powerhead model. [space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Anderson, P. G.; Farmer, R. C.

    1985-01-01

    A three dimensional analysis of the non-uniform flow around the liquid oxygen (LOX) posts in the Space Shuttle Main Engine (SSME) powerhead was performed to determine possible factors contributing to the failure of the posts. Also performed was three dimensional numerical fluid flow analysis of the high pressure fuel turbopump (HPFTP) exhaust system, consisting of the turnaround duct (TAD), two-duct hot gas manifold (HGM), and the Version B transfer ducts. The analysis was conducted in the following manner: (1) modeling the flow around a single and small clusters (2 to 10) of posts; (2) modeling the velocity field in the cross plane; and (3) modeling the entire flow region with a three dimensional network type model. Shear stress functions which will permit viscous analysis without requiring excessive numbers of computational grid points were developed. These wall functions, laminar and turbulent, have been compared to standard Blasius solutions and are directly applicable to the cylinder in cross flow class of problems to which the LOX post problem belongs.

  5. Use of an expert system data analysis manager for space shuttle main engine test evaluation

    NASA Technical Reports Server (NTRS)

    Abernethy, Ken

    1988-01-01

    The ability to articulate, collect, and automate the application of the expertise needed for the analysis of space shuttle main engine (SSME) test data would be of great benefit to NASA liquid rocket engine experts. This paper describes a project whose goal is to build a rule-based expert system which incorporates such expertise. Experiential expertise, collected directly from the experts currently involved in SSME data analysis, is used to build a rule base to identify engine anomalies similar to those analyzed previously. Additionally, an alternate method of expertise capture is being explored. This method would generate rules inductively based on calculations made using a theoretical model of the SSME's operation. The latter rules would be capable of diagnosing anomalies which may not have appeared before, but whose effects can be predicted by the theoretical model.

  6. Reliability growth modeling analysis of the space shuttle main engines based upon the Weibull process

    NASA Technical Reports Server (NTRS)

    Wheeler, J. T.

    1990-01-01

    The Weibull process, identified as the inhomogeneous Poisson process with the Weibull intensity function, is used to model the reliability growth assessment of the space shuttle main engine test and flight failure data. Additional tables of percentage-point probabilities for several different values of the confidence coefficient have been generated for setting (1-alpha)100-percent two sided confidence interval estimates on the mean time between failures. The tabled data pertain to two cases: (1) time-terminated testing, and (2) failure-terminated testing. The critical values of the three test statistics, namely Cramer-von Mises, Kolmogorov-Smirnov, and chi-square, were calculated and tabled for use in the goodness of fit tests for the engine reliability data. Numerical results are presented for five different groupings of the engine data that reflect the actual response to the failures.

  7. The main problems in the mechanical engineering sector and some possible directions of their solution

    NASA Astrophysics Data System (ADS)

    Strizhakova, E.

    2016-04-01

    The article shows the problems of the sector of mechanical engineering in the industrial system in Russia. The author's method of estimating the relative level of risk and the method of determining the de-industrialization degree of the sector based on the aggregated level of adaptability are given. According to them we have analysed the key indicators, such as basic, developed and advanced technologies, and investments in an old or new technology of industrial sectors. The main directions of the impact of industrial policy allowing a change in the current situation in mechanical engineering are given. The results can be applied in practice in formation of directions and actual control actions to improve the overall efficiency of mechanical engineering industry.

  8. Investigation of instability, dynamic forces, and effect of dynamic loading on strength of cages for the bearings in the high pressure oxygen turbopumps for the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Dufrane, K. F.; Kannel, J. W.; Merriman, T. L.; Rosenfield, A. R.

    1985-01-01

    Experiments were performed to determine the effect of cyclic loading on bearing cage strength. A long term working tensile load of approximately 1300 N (300 lbs) was found to be the likely maximum. Higher loads caused a decrease in cage tensile strength after the 125,000 cycle testing period. Poisson's ratio in compression was found to be highly dependent upon the direction of the fiberglass plies. At room temperature the value was 0.15 with the plies and 0.68 across the plies. At -196 C (-321 F), the value with the plies was 0.20. The results of the analyses conducted have again demonstrated the critical need for improved lubrication in the high pressure oxygen turbopump bearings. Lubricant films with low shear strength and low friction coefficients promote cage stability and decrease ball/cage forces during marginal operating conditions. The analysis of the effect of combined bearing loads on ball/cage loads has identified a radial load of 3600 N (800 lbs) as the maximum for the current clearance of the balls and cage pockets. Liquid oxygen impinging on the cage in the direction of rotation was found to enhance cage stability.

  9. Fermilab main injector: High intensity operation and beam loss control

    NASA Astrophysics Data System (ADS)

    Brown, Bruce C.; Adamson, Philip; Capista, David; Chou, Weiren; Kourbanis, Ioanis; Morris, Denton K.; Seiya, Kiyomi; Wu, Guan Hong; Yang, Ming-Jen

    2013-07-01

    From 2005 through 2012, the Fermilab Main Injector provided intense beams of 120 GeV protons to produce neutrino beams and antiprotons. Hardware improvements in conjunction with improved diagnostics allowed the system to reach sustained operation at 400 kW beam power. Transmission was very high except for beam lost at or near the 8 GeV injection energy where 95% beam transmission results in about 1.5 kW of beam loss. By minimizing and localizing loss, residual radiation levels fell while beam power was doubled. Lost beam was directed to either the collimation system or to the beam abort. Critical apertures were increased while improved instrumentation allowed optimal use of available apertures. We will summarize the improvements required to achieve high intensity, the impact of various loss control tools and the status and trends in residual radiation in the Main Injector.

  10. Real gas properties and Space Shuttle Main Engine fuel turbine performance prediction

    NASA Technical Reports Server (NTRS)

    Harloff, G. J.

    1987-01-01

    The H2/H2O mixture thermodynamic and transport properties variations for the Space Shuttle Main Engine (SSME) fuel turbine over a range of temperatures and pressures are examined. The variation of molecular viscosity, specific heat at constant pressure, and Prandtl number for the hydrogen/steam mixture are fitted using polynominal relationships for future turbine performance use. The mixture property variations are calculated using GASP and WASP computer programs. The air equivalent performance of the SSME fuel turbine is computed.

  11. Phased Array Ultrasonic Examination of Space Shuttle Main Engine Nozzle Weld

    NASA Technical Reports Server (NTRS)

    James, S.; Engel, J.; Kimbrough, D.; Suits, M.; McCool, Alex (Technical Monitor)

    2001-01-01

    This paper describes a Phased Array Ultrasonic Examination that was developed for the examination of a limited access circumferential Inconel 718 fusion weld of a Space Shuttle Main Engine Nozzle - Cone. The paper discusses the selection and formation criteria used for the phased array focal laws, the reference standard that simulated hardware conditions, the examination concept, and results. Several unique constraints present during this examination included limited probe movement to a single axis and one-sided access to the weld.

  12. High frequency dynamic engine simulation. [TF-30 engine

    NASA Technical Reports Server (NTRS)

    Schuerman, J. A.; Fischer, K. E.; Mclaughlin, P. W.

    1977-01-01

    A digital computer simulation of a mixed flow, twin spool turbofan engine was assembled to evaluate and improve the dynamic characteristics of the engine simulation to disturbance frequencies of at least 100 Hz. One dimensional forms of the dynamic mass, momentum and energy equations were used to model the engine. A TF30 engine was simulated so that dynamic characteristics could be evaluated against results obtained from testing of the TF30 engine at the NASA Lewis Research Center. Dynamic characteristics of the engine simulation were improved by modifying the compression system model. Modifications to the compression system model were established by investigating the influence of size and number of finite dynamic elements. Based on the results of this program, high frequency engine simulations using finite dynamic elements can be assembled so that the engine dynamic configuration is optimum with respect to dynamic characteristics and computer execution time. Resizing of the compression systems finite elements improved the dynamic characteristics of the engine simulation but showed that additional refinements are required to obtain close agreement simulation and actual engine dynamic characteristics.

  13. A data base and analysis program for shuttle main engine dynamic pressure measurements. Appendix B: Data base plots for SSME tests 901-290 through 901-414

    NASA Technical Reports Server (NTRS)

    Coffin, T.

    1986-01-01

    A dynamic pressure data base and data base management system developed to characterize the Space Shuttle Main Engine (SSME) dynamic pressure environment is described. The data base represents dynamic pressure measurements obtained during single engine hot firing tesets of the SSME. Software is provided to permit statistical evaluation of selected measurements under specified operating conditions. An interpolation scheme is also included to estimate spectral trends with SSME power level. Flow dynamic environments in high performance rocket engines are discussed.

  14. A data base and analysis program for shuttle main engine dynamic pressure measurements. Appendix C: Data base plots for SSME tests 902-214 through 902-314

    NASA Technical Reports Server (NTRS)

    Coffin, T.

    1986-01-01

    A dynamic pressure data base and data base management system developed to characterize the Space Shuttle Main Engine (SSME) dynamic pressure environment is reported. The data base represents dynamic pressure measurements obtained during single engine hot firing tests of the SSME. Software is provided to permit statistical evaluation of selected measurements under specified operating conditions. An interpolation scheme is included to estimate spectral trends with SSME power level. Flow Dynamic Environments in High Performance Rocket Engines are described.

  15. Algorithms for real-time fault detection of the Space Shuttle Main Engine

    NASA Astrophysics Data System (ADS)

    Ruiz, C. A.; Hawman, M. W.; Galinaitis, W. S.

    1992-07-01

    This paper reports on the results of a program to develop and demonstrate concepts related to a realtime health management system (HMS) for the Space Shuttle Main Engine (SSME). An HMS framework was developed on the basis of a top-down analysis of the current rocket engine failure modes and the engine monitoring requirements. One result of Phase I of this program was the identification of algorithmic approaches for detecting failures of the SSME. Three different analytical techniques were developed which demonstrated the capability to detect failures significantly earlier than the existing redlines. Based on promising initial results, Phase II of the program was initiated to further validate and refine the fault detection strategy on a large data base of 140 SSME test firings, and implement the resultant algorithms in real time. The paper begins with an overview of the refined algorithms used to detect failures during SSME start-up and main-stage operation. Results of testing these algorithms on a data base of nominal and off-nominal SSME test firings is discussed. The paper concludes with a discussion of the performance of the algorithms operating on a real-time computer system.

  16. Algorithms for real-time fault detection of the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Ruiz, C. A.; Hawman, M. W.; Galinaitis, W. S.

    1992-01-01

    This paper reports on the results of a program to develop and demonstrate concepts related to a realtime health management system (HMS) for the Space Shuttle Main Engine (SSME). An HMS framework was developed on the basis of a top-down analysis of the current rocket engine failure modes and the engine monitoring requirements. One result of Phase I of this program was the identification of algorithmic approaches for detecting failures of the SSME. Three different analytical techniques were developed which demonstrated the capability to detect failures significantly earlier than the existing redlines. Based on promising initial results, Phase II of the program was initiated to further validate and refine the fault detection strategy on a large data base of 140 SSME test firings, and implement the resultant algorithms in real time. The paper begins with an overview of the refined algorithms used to detect failures during SSME start-up and main-stage operation. Results of testing these algorithms on a data base of nominal and off-nominal SSME test firings is discussed. The paper concludes with a discussion of the performance of the algorithms operating on a real-time computer system.

  17. Booster Main Engine Selection Criteria for the Liquid Fly-Back Booster

    NASA Technical Reports Server (NTRS)

    Ryan, Richard M.; Rothschild, William J.; Christensen, David L.

    1998-01-01

    The Liquid Fly-Back Booster (LFBB) Program seeks to enhance the Space Shuttle system safety performance and economy of operations through the use of an advanced, liquid propellant Booster Main Engine (BME). There are several viable BME candidates that could be suitable for this application. The objective of this study was to identify the key criteria to be applied in selecting among these BME candidates. This study involved an assessment of influences on the overall LFBB utility due to variations in the candidate rocket engines' characteristics. This includes BME impacts on vehicle system weight, perfortnance,design approaches, abort modes, margins of safety, engine-out operations, and maintenance and support concepts. Systems engineering analyses and trade studies were performed to identify the LFBB system level sensitivities to a wide variety of BME related parameters. This presentation summarizes these trade studies and the resulting findings of the LFBB design teams regarding the BME characteristics that most significantly affect the LFBB system. The resulting BME choice should offer the best combination of reliability, performance, reusability, robustness, cost, and risk for the LFBB program.

  18. Booster Main Engine Selection Criteria for the Liquid Fly-Back Booster

    NASA Technical Reports Server (NTRS)

    Ryan, Richard M.; Rothschild, William J.; Christensen, David L.

    1998-01-01

    The Liquid Fly-Back Booster (LFBB) Program seeks to enhance the Space Shuttle system safety, performance and economy of operations through the use of an advanced, liquid propellant Booster Main Engine (BME). There are several viable BME candidates that could be suitable for this application. The objective of this study was to identify the key Criteria to be applied in selecting among these BME candidates. This study involved an assessment of influences on the overall LFBB utility due to variations in the candidate rocket-engines characteristics. This includes BME impacts on vehicle system weight, performance, design approaches, abort modes, margins of safety, engine-out operations, and maintenance and support concepts. Systems engineering analyses and trade studies were performed to identify the LFBB system level sensitivities to a wide variety of BME related parameters. This presentation summarizes these trade studies and the resulting findings of the LFBB design teams regarding the BME characteristics that most significantly affect the LFBB system. The resulting BME choice should offer the best combination of reliability, performance, reusability, robustness, cost, and risk for the LFBB program.

  19. Structural integrity and durability for Space Shuttle main engine and future reusable space propulsion systems

    NASA Technical Reports Server (NTRS)

    Marsik, S. J.; Gawrylowicz, H. T.

    1986-01-01

    NASA is conducting a program which will establish a technology base for the orderly evolution of reusable space propulsion systems. As part of that program, NASA initiated a Structural Integrity and Durability effort for advanced high-pressure oxygen-hydrogen rocket engine technology. That effort focuses on the development of: (1) accurate analytical models to describe flow fields; aerothermodynamic loads; structural responses; and fatigue/fracture, from which life prediction codes can be evolved; and (2) advanced instrumentation with capabilities to verify the codes in an SSME-like environment as well as the potential for future use as diagnostic sensors for real-time condition monitoring of critical engine components.

  20. Operating manual for coaxial injection combustion model. [for the space shuttle main engine

    NASA Technical Reports Server (NTRS)

    Sutton, R. D.; Schuman, M. D.; Chadwick, W. D.

    1974-01-01

    An operating manual for the coaxial injection combustion model (CICM) is presented as the final report for an eleven month effort designed to provide improvement, to verify, and to document the comprehensive computer program for analyzing the performance of thrust chamber operation with gas/liquid coaxial jet injection. The effort culminated in delivery of an operation FORTRAN IV computer program and associated documentation pertaining to the combustion conditions in the space shuttle main engine. The computer program is structured for compatibility with the standardized Joint Army-Navy-NASA-Air Force (JANNAF) performance evaluation procedure. Use of the CICM in conjunction with the JANNAF procedure allows the analysis of engine systems using coaxial gas/liquid injection.

  1. Off-line programming motion and process commands for robotic welding of Space Shuttle main engines

    NASA Technical Reports Server (NTRS)

    Ruokangas, C. C.; Guthmiller, W. A.; Pierson, B. L.; Sliwinski, K. E.; Lee, J. M. F.

    1987-01-01

    The off-line-programming software and hardware being developed for robotic welding of the Space Shuttle main engine are described and illustrated with diagrams, drawings, graphs, and photographs. The menu-driven workstation-based interactive programming system is designed to permit generation of both motion and process commands for the robotic workcell by weld engineers (with only limited knowledge of programming or CAD systems) on the production floor. Consideration is given to the user interface, geometric-sources interfaces, overall menu structure, weld-parameter data base, and displays of run time and archived data. Ongoing efforts to address limitations related to automatic-downhand-configuration coordinated motion, a lack of source codes for the motion-control software, CAD data incompatibility, interfacing with the robotic workcell, and definition of the welding data base are discussed.

  2. A high performance thermoacoustic engine

    NASA Astrophysics Data System (ADS)

    Tijani, M. E. H.; Spoelstra, S.

    2011-11-01

    In thermoacoustic systems heat is converted into acoustic energy and vice versa. These systems use inert gases as working medium and have no moving parts which makes the thermoacoustic technology a serious alternative to produce mechanical or electrical power, cooling power, and heating in a sustainable and environmentally friendly way. A thermoacoustic Stirling heat engine is designed and built which achieves a record performance of 49% of the Carnot efficiency. The design and performance of the engine is presented. The engine has no moving parts and is made up of few simple components.

  3. Space shuttle main engine definition (phase B). Volume 5: Valves and interconnects. [for space shuttle

    NASA Technical Reports Server (NTRS)

    Schultz, D. F.

    1971-01-01

    The steady state thermodynamic cycle balance of the single preburner staged combustion engine, coupled with dynamic transient analyses, dictated in detail the location and requirements for each valve defined in this volume. Valve configuration selections were influenced by overall engine and vehicle system weight and failure mode determinations. Modulating valve actuators are external to the valve and are line replaceable. Development and satisfactory demonstration of a high pressure dynamic shaft seal has made this configuration practical. Pneumatic motor driven actuators that use engine pumped hydrogen gas as the working fluid are used. The helium control system is proposed as a module containing a cluster of solenoid actuated valves. The separable couplings and flanges are designed to assure minimum leakage with minimum coupling weight. The deflection of the seal surface in the flange is defined by finite element analysis that has been confirmed with test data. The seal design proposed has passed preliminary pressure cycling and thermal cycling tests.

  4. Pratt and Whitney Rocketdyne Space Shuttle Main Engine Heritage Commemorative: Powerhead and Ducts, Test and Flight Operations

    NASA Technical Reports Server (NTRS)

    Cook, Jerry R.; Willis, Martha

    2009-01-01

    The videos (Powerhead and Ducts, Test and Flight Operations) review the Space Shuttle Main Engine (SSME) program from Pratt and Whitney Rocketdyne. They include highlights from the engine's development and lifecycle through the engine testing to the deployment in the space shuttle.

  5. Spares Management : Optimizing Hardware Usage for the Space Shuttle Main Engine

    NASA Technical Reports Server (NTRS)

    Gulbrandsen, K. A.

    1999-01-01

    The complexity of the Space Shuttle Main Engine (SSME), combined with mounting requirements to reduce operations costs have increased demands for accurate tracking, maintenance, and projections of SSME assets. The SSME Logistics Team is developing an integrated asset management process. This PC-based tool provides a user-friendly asset database for daily decision making, plus a variable-input hardware usage simulation with complex logic yielding output that addresses essential asset management issues. Cycle times on critical tasks are significantly reduced. Associated costs have decreased as asset data quality and decision-making capability has increased.

  6. Investigations for the improvement of space shuttle main engine electron beam welding equipment

    NASA Technical Reports Server (NTRS)

    Smock, R. A.; Taylor, R. A.; Wall, W. A., Jr.

    1977-01-01

    Progress made in the testing, evaluation, and correction of MSFC's 7.5 kW electron beam welder in support of space shuttle main engine component welding is summarized. The objective of this project was to locate and correct the deficiencies in the welder. Some 17 areas were deficient in the 7.5 kW ERI welding system and the associated corrective action was taken to improve its operational performance. An overall improvement of 20 times the original reliability was obtained at full rated capacity after the modifications were made.

  7. Space Shuttle Main Engine plume diagnostics: OPAD approach to vehicle health monitoring

    NASA Astrophysics Data System (ADS)

    Powers, W. T.; Cooper, A. E.; Wallace, T. L.; Buntine, W. L.; Whitaker, K.

    The process of applying spectroscopy to the Space Shuttle Main Engine (SSME) for plume diagnostics, as it exists today, originated at Marshall Space Flight Center in Huntsville, Alabama, and its implementation was assured largely through the efforts of Sverdrup, AEDC, in Tullahoma, Tennessee. This process, Optical Plume Anomaly Detection (OPAD), has formed the basis for various efforts in the development of in-flight plume spectroscopy and in addition produced a viable test stand vehicle health monitor. The purpose of this paper will be to provide an introduction to the OPAD system by discussing the process of obtaining data as well as the methods of examining and interpreting the data.

  8. Thrust chamber performance using Navier-Stokes solution. [space shuttle main engine viscous nozzle calculation

    NASA Technical Reports Server (NTRS)

    Chan, J. S.; Freeman, J. A.

    1984-01-01

    The viscous, axisymmetric flow in the thrust chamber of the space shuttle main engine (SSME) was computed on the CRAY 205 computer using the general interpolants method (GIM) code. Results show that the Navier-Stokes codes can be used for these flows to study trends and viscous effects as well as determine flow patterns; but further research and development is needed before they can be used as production tools for nozzle performance calculations. The GIM formulation, numerical scheme, and computer code are described. The actual SSME nozzle computation showing grid points, flow contours, and flow parameter plots is discussed. The computer system and run times/costs are detailed.

  9. Validation of the space shuttle main engine steady state performance model

    NASA Technical Reports Server (NTRS)

    Santi, L. Michael

    1990-01-01

    The primary objective was to present methods for validating predictions of Rocketdyne's most current version of the Space Shuttle Main Engine (SSME) Power Balance Model (PBM) with respect to physical relations governing flow systems. This required the development and implementation of postprocessors to check results of PBM computations for satisfaction of conservation relations. A cursory uncertainty analysis of PBM predictions with respect to mass and energy balances was performed. In addition, an effort to identify the empirical relations and physical assumptions within PBM which impact the ability of the model to attain rigorous balance was begun.

  10. Study of hydraulic actuation system for Space Shuttle main engine propellant valves

    NASA Technical Reports Server (NTRS)

    Ewel, Bob (Editor)

    1993-01-01

    Recent performance concerns involving the Space Shuttle Main Engine Propellant Valve Actuator assemblies prompted the NASA Marshall Space Flight Center to request an independent design assessment. Moog Inc. responded to this request and received a study contract with objectives of increasing valve reliability, decreasing maintenance costs while preserving the existing design interfaces. The results of the Propellant Valve Actuation System review focus on contamination control and the bypass valve design. Three proof of concept bypass valves employing design changes were built and successfully tested. Test results are presented.