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

Application of fault factor method to fault detection and diagnosis for space shuttle main engine

NASA Astrophysics Data System (ADS)

Cha, Jihyoung; Ha, Chulsu; Ko, Sangho; Koo, Jaye

2016-09-01

This paper deals with an application of the multiple linear regression algorithm to fault detection and diagnosis for the space shuttle main engine (SSME) during a steady state. In order to develop the algorithm, the energy balance equations, which balances the relation among pressure, mass flow rate and power at various locations within the SSME, are obtained. Then using the measurement data of some important parameters of the engine, fault factors which reflects the deviation of each equation from the normal state are estimated. The probable location of each fault and the levels of severity can be obtained from the estimated fault factors. This process is numerically demonstrated for the SSME at 104% Rated Propulsion Level (RPL) by using the simulated measurement data from the mathematical models of the engine. The result of the current study is particularly important considering that the recently developed reusable Liquid Rocket Engines (LREs) have staged-combustion cycles similarly to the SSME.

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.

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.

Evaluation of SSME test data reduction methods

NASA Technical Reports Server (NTRS)

Santi, L. Michael

1994-01-01

Accurate prediction of hardware and flow characteristics within the Space Shuttle Main Engine (SSME) during transient and main-stage operation requires a significant integration of ground test data, flight experience, and computational models. The process of integrating SSME test measurements with physical model predictions is commonly referred to as data reduction. Uncertainties within both test measurements and simplified models of the SSME flow environment compound the data integration problem. The first objective of this effort was to establish an acceptability criterion for data reduction solutions. The second objective of this effort was to investigate the data reduction potential of the ROCETS (Rocket Engine Transient Simulation) simulation platform. A simplified ROCETS model of the SSME was obtained from the MSFC Performance Analysis Branch . This model was examined and tested for physical consistency. Two modules were constructed and added to the ROCETS library to independently check the mass and energy balances of selected engine subsystems including the low pressure fuel turbopump, the high pressure fuel turbopump, the low pressure oxidizer turbopump, the high pressure oxidizer turbopump, the fuel preburner, the oxidizer preburner, the main combustion chamber coolant circuit, and the nozzle coolant circuit. A sensitivity study was then conducted to determine the individual influences of forty-two hardware characteristics on fourteen high pressure region prediction variables as returned by the SSME ROCETS model.

Materials and processes for shuttle engine, external tank, and solid rocket booster

NASA Technical Reports Server (NTRS)

Schwinghamer, R. J.

1977-01-01

The Shuttle flight system is composed of the Orbiter, an External Tank (ET) that contains the ascent propellant to be used by the Space Shuttle Main Engines (SSME), and two Solid Rocket Boosters (SRB). The ET is expended on each launch; the Orbiter and SRB's are reusable. It is the requirement for reuse which poses the exciting new materials and processes challenges in the development of the Space Shuttle. A brief description of the Space Shuttle and the mission profile is given. The Shuttle configuration is then described with emphasis on the SSME, ET, and SRB. The materials selection, tracking, and control system used to assure reliability and to minimize cost are described, and salient features and challenges in materials and processes associated with the SSME, ET, and SRB are subsequently discussed.

Tripropellant Engine Study

NASA Technical Reports Server (NTRS)

Wheeler, D. B.

1977-01-01

The feasibility of modifying the space shuttle main engine (SSME) for dual mode operation was investigated. Various high power cycle engine configurations derived from the SSME were configurations that will allow sequential burning of LOX/hydrocarbon and LOX/hydrogen were studied in order to identify concepts that make maximum use of SSME hardware and best satisfy the dual mode booster engine system application. Engine cycles were formulated for LOX/RP-1, LOX/CH4, and LOX/C3H8 propellants. Flow rates and operating cycles were established and the adaptability of the major components of the SSME was evaluated.

KSC-04PD-2511

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Orbiter Processing Facility, a technician appears to ride the Space Shuttle Main Engine (SSME) as he maneuvers the SSME on the Hyster lift into position for installation on Discovery, the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

KSC-04PD-2513

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Orbiter Processing Facility, a technician appears to ride the Space Shuttle Main Engine (SSME) as he maneuvers the SSME on the Hyster lift into position for installation on Discovery, the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

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 electronic manual that contains all the required data and illustrations in expanded view format using standard PC products (Word, Excel, PDF, Photoshop). The logistics of accurately releasing this information to field personnel was greatly enhanced via the utilization of common office products to produce a more user-friendly format than was originally developed under contract to NASA. This was done without reinventing the system, which would be cost prohibitive on a program of this maturity. The brunt of the joint part tracking is done within the logistics organization and disseminated to all field sites, without duplicating effort at each site. The JDL is easily accessible across the country via the NASA intranet directly at the SSME workstand. The advent of this logistics data product has greatly enhanced the reliability of tracking dynamic changes to the SSME and greatly reduces engineering change turnaround time and potential for errors. Since the inception of the JDL system in 1997, no discrepant parts have propagated to engine assembly operations. This presentation focuses on the challenges overcome and the techniques used to apply today's desktop technologies to an existing logistics data source.

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.

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.

General view of the High Bay area of the Space ...

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

General view of the High Bay area of the Space Shuttle Main Engine (SSME) Processing Facility at Kennedy Space Center. This view shows the specially modified fork lift used for horizontal installation and removal of the SSMEs into and out of the Orbiters. SSME number 2059 is in the background and is in the process of being scanned with a high-definition laser scanner to acquire field documentation for the production of historic documentatin. - Space Transportation System, Space Shuttle Main Engine, Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

KSC-95PC585

NASA Image and Video Library

1995-04-17

KENNEDY SPACE CENTER, FLA. - A Space Shuttle Main Engine (SSME) hoist prepares to lift the first Block 1 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 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 exchanger and start sequence modifications. The other two main engines to be used during the liftoff of the STS-70 mission are of the existing Phase II design.

Cost effective launch operations of the SSME

NASA Technical Reports Server (NTRS)

Klatt, F. P.

1985-01-01

The Space Shuttle Main Engine (SSME) represents the beginning of reusable rocket engine operations in the space transportation system (STS). Steps taken to reduce the overall cost of flight operations of the SSME by improving turnaround operations, extending the life of the engine, and improving the cost effectiveness of overhaul operations at the Canoga Park home plant are described. Ground certification testing to ensure safe launch operations is described, as well as certification extension testing that leads to a service life equivalent to 40 flights. The proven flight record of the SSME, which has demonstrated the utility of the SSME as a key component of America's space transportation system, is discussed.

A data base and analysis program for shuttle main engine dynamic pressure measurements. Appendix F: Data base plots for SSME tests 750-120 through 750-200

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 presented. 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 also included to estimate spectral trends with SSME power level.

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.

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.

SSME Post Test Diagnostic System: Systems Section

NASA Technical Reports Server (NTRS)

Bickmore, Timothy

1995-01-01

An assessment of engine and component health is routinely made after each test firing or flight firing of a Space Shuttle Main Engine (SSME). Currently, this health assessment is done by teams of engineers who manually review sensor data, performance data, and engine and component operating histories. Based on review of information from these various sources, an evaluation is made as to the health of each component of the SSME and the preparedness of the engine for another test or flight. The objective of this project - the SSME Post Test Diagnostic System (PTDS) - is to develop a computer program which automates the analysis of test data from the SSME in order to detect and diagnose anomalies. This report primarily covers work on the Systems Section of the PTDS, which automates the analyses performed by the systems/performance group at the Propulsion Branch of NASA Marshall Space Flight Center (MSFC). This group is responsible for assessing the overall health and performance of the engine, and detecting and diagnosing anomalies which involve multiple components (other groups are responsible for analyzing the behavior of specific components). The PTDS utilizes several advanced software technologies to perform its analyses. Raw test data is analyzed using signal processing routines which detect features in the data, such as spikes, shifts, peaks, and drifts. Component analyses are performed by expert systems, which use 'rules-of-thumb' obtained from interviews with the MSFC data analysts to detect and diagnose anomalies. The systems analysis is performed using case-based reasoning. Results of all analyses are stored in a relational database and displayed via an X-window-based graphical user interface which provides ranked lists of anomalies and observations by engine component, along with supporting data plots for each.

Closeup view of the aft fuselage of the Orbiter Discovery ...

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

Close-up view of the aft fuselage of the Orbiter Discovery looking at the thrust structure that supports the Space Shuttle Main Engines (SSMEs). In this view, SSME number two position is on the left and SSME number three position is on the right. The thrust structure transfers the forces produce by the engines into and through the airframe of the orbiter. The thrust structure includes the SSMEs load reaction truss structure, engine interface fittings and the hydraulic-actuator support structure. The propellant feed lines are the plugged and capped orifices within the engine bays. Note that SSME position two is rotated ninety degrees from position three and one. This was needed to enable enough clearance for the engines to fit and gimbal. Note in engine bay three is a clear view of the actuators that control the gambling of that engine. This view was taken from a service platform in the Orbiter Processing Facility at Kennedy Space Center. - Space Transportation System, Orbiter Discovery (OV-103), Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

KSC-04pd1646

NASA Image and Video Library

2004-08-03

KENNEDY SPACE CENTER, FLA. - In the Space Shuttle Main Engine (SSME) Processing Facility, Boeing-Rocketdyne crane operator Joe Ferrante (left) lowers SSME 2058, the first SSME fully assembled at KSC, onto an engine stand with the assistance of other technicians on his team. The engine is being moved from its vertical work stand into a horizontal position in preparation for shipment to NASA’s Stennis Space Center in Mississippi to undergo a hot fire acceptance test. It is the first of five engines to be fully assembled on site to reach the desired number of 15 engines ready for launch at any given time in the Space Shuttle program. A Space Shuttle has three reusable main engines. Each is 14 feet long, weighs about 7,800 pounds, is seven-and-a-half feet in diameter at the end of its nozzle, and generates almost 400,000 pounds of thrust. Historically, SSMEs were assembled in Canoga Park, Calif., with post-flight inspections performed at KSC. Both functions were consolidated in February 2002. The Rocketdyne Propulsion and Power division of The Boeing Co. manufactures the engines for NASA.

KSC-04PD-1648

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Space Shuttle Main Engine (SSME) Processing Facility, Boeing-Rocketdyne quality inspector Nick Grimm (center) monitors the work of technicians on his team as they lower SSME 2058, the first SSME fully assembled at KSC, onto an engine stand. The engine is being placed into a horizontal position in preparation for shipment to NASAs Stennis Space Center in Mississippi to undergo a hot fire acceptance test. It is the first of five engines to be fully assembled on site to reach the desired number of 15 engines ready for launch at any given time in the Space Shuttle program. A Space Shuttle has three reusable main engines. Each is 14 feet long, weighs about 7,800 pounds, is seven-and-a-half feet in diameter at the end of its nozzle, and generates almost 400,000 pounds of thrust. Historically, SSMEs were assembled in Canoga Park, Calif., with post-flight inspections performed at KSC. Both functions were consolidated in February 2002. The Rocketdyne Propulsion and Power division of The Boeing Co. manufactures the engines for NASA.

KSC-04pd1648

NASA Image and Video Library

2004-08-03

KENNEDY SPACE CENTER, FLA. - In the Space Shuttle Main Engine (SSME) Processing Facility, Boeing-Rocketdyne quality inspector Nick Grimm (center) monitors the work of technicians on his team as they lower SSME 2058, the first SSME fully assembled at KSC, onto an engine stand. The engine is being placed into a horizontal position in preparation for shipment to NASA’s Stennis Space Center in Mississippi to undergo a hot fire acceptance test. It is the first of five engines to be fully assembled on site to reach the desired number of 15 engines ready for launch at any given time in the Space Shuttle program. A Space Shuttle has three reusable main engines. Each is 14 feet long, weighs about 7,800 pounds, is seven-and-a-half feet in diameter at the end of its nozzle, and generates almost 400,000 pounds of thrust. Historically, SSMEs were assembled in Canoga Park, Calif., with post-flight inspections performed at KSC. Both functions were consolidated in February 2002. The Rocketdyne Propulsion and Power division of The Boeing Co. manufactures the engines for NASA.

Space Shuttle main engine OPAD: The search for a hardware enhanced plume

NASA Astrophysics Data System (ADS)

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

1993-11-01

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 team continues to lead and guide efforts in the plume diagnostics arena. The process, Optical Plume Anomaly Detection (OPAD), formed the basis for various activities in the development of ground-based systems as well as the development of in-flight plume spectroscopy. OPAD currently provides and will continue to provide valuable information relative to future systems definitions, instrumentation development, code validation, and data diagnostic processing. OPAD is based on the detection of anomalous atomic and molecular species in the SSME plume using two complete, stand-alone optical spectrometers. To-date OPAD has acquired data on 44 test firings of the SSME at the Technology Test Bed (TTB) at MSFC. 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. It will encompass such issues as selection of instrumentation correlation of data to nominal engine operation, investigation of SSME component erosion via OPAD spectral data, necessity and benefits of plume seeding, application of artificial intelligence (AI) techniques to data analysis, and the present status of efforts to quantify specie erosion utilizing standard plume and chemistry codes as well as radiative models currently under development.

Space Shuttle main engine OPAD: The search for a hardware enhanced plume

NASA Technical Reports Server (NTRS)

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

1993-01-01

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 team continues to lead and guide efforts in the plume diagnostics arena. The process, Optical Plume Anomaly Detection (OPAD), formed the basis for various activities in the development of ground-based systems as well as the development of in-flight plume spectroscopy. OPAD currently provides and will continue to provide valuable information relative to future systems definitions, instrumentation development, code validation, and data diagnostic processing. OPAD is based on the detection of anomalous atomic and molecular species in the SSME plume using two complete, stand-alone optical spectrometers. To-date OPAD has acquired data on 44 test firings of the SSME at the Technology Test Bed (TTB) at MSFC. 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. It will encompass such issues as selection of instrumentation correlation of data to nominal engine operation, investigation of SSME component erosion via OPAD spectral data, necessity and benefits of plume seeding, application of artificial intelligence (AI) techniques to data analysis, and the present status of efforts to quantify specie erosion utilizing standard plume and chemistry codes as well as radiative models currently under development.

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.

Analysis of SSME HPOTP rotordynamics subsynchronous whirl

NASA Technical Reports Server (NTRS)

1984-01-01

The causes and remedies of vibration and subsynchronous whirl problems encountered in the Shuttle Main Engine SSME turbomachinery are analyzed. Because the nonlinear and linearized models of the turbopumps play such an important role in the analysis process, the main emphasis is concentrated on the verification and improvement of these tools. It has been the goal of our work to validate the equations of motion used in the models are validated, including the assumptions upon which they are based. Verification of th SSME rotordynamics simulation and the developed enhancements, are emphasized.

Engine Data Interpretation System (EDIS)

NASA Technical Reports Server (NTRS)

Cost, Thomas L.; Hofmann, Martin O.

1990-01-01

A prototype of an expert system was developed which applies qualitative or model-based reasoning to the task of post-test analysis and diagnosis of data resulting from a rocket engine firing. A combined component-based and process theory approach is adopted as the basis for system modeling. Such an approach provides a framework for explaining both normal and deviant system behavior in terms of individual component functionality. The diagnosis function is applied to digitized sensor time-histories generated during engine firings. The generic system is applicable to any liquid rocket engine but was adapted specifically in this work to the Space Shuttle Main Engine (SSME). The system is applied to idealized data resulting from turbomachinery malfunction in the SSME.

KSC-04pd1645

NASA Image and Video Library

2004-08-03

KENNEDY SPACE CENTER, FLA. - In the Space Shuttle Main Engine (SSME) Processing Facility, Boeing-Rocketdyne crane operator Joe Ferrante (second from right) lifts SSME 2058, the first SSME fully assembled at KSC, with the assistance of other technicians on his team. The engine is being lifted from its vertical work stand into a horizontal position in preparation for shipment to NASA’s Stennis Space Center in Mississippi to undergo a hot fire acceptance test. It is the first of five engines to be fully assembled on site to reach the desired number of 15 engines ready for launch at any given time in the Space Shuttle program. A Space Shuttle has three reusable main engines. Each is 14 feet long, weighs about 7,800 pounds, is seven-and-a-half feet in diameter at the end of its nozzle, and generates almost 400,000 pounds of thrust. Historically, SSMEs were assembled in Canoga Park, Calif., with post-flight inspections performed at KSC. Both functions were consolidated in February 2002. The Rocketdyne Propulsion and Power division of The Boeing Co. manufactures the engines for NASA.

Engineering evaluation of SSME dynamic data from engine tests and SSV flights

NASA Technical Reports Server (NTRS)

1986-01-01

An engineering evaluation of dynamic data from SSME hot firing tests and SSV flights is summarized. The basic objective of the study is to provide analyses of vibration, strain and dynamic pressure measurements in support of MSFC performance and reliability improvement programs. A brief description of the SSME test program is given and a typical test evaluation cycle reviewed. Data banks generated to characterize SSME component dynamic characteristics are described and statistical analyses performed on these data base measurements are discussed. Analytical models applied to define the dynamic behavior of SSME components (such as turbopump bearing elements and the flight accelerometer safety cut-off system) are also summarized. Appendices are included to illustrate some typical tasks performed under this study.

Faces of the SSME (Group 2)

NASA Technical Reports Server (NTRS)

2010-01-01

Members of the Space Shuttle Main Engine (SSME) team review some of their memories of working on the SSME and the importance of the SSME to the success of the Shuttle program. There are many views of shuttle launches.

Faces of SSME (Group 13)

NASA Technical Reports Server (NTRS)

2009-01-01

Members of the Space Shuttle Main Engine (SSME) team review some of their memories of working on the SSME and the importance of the SSME to the success of the Shuttle program. There are many views of shuttle launches.

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.

KSC-04PD-2515

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In this view from the floor of the Orbiter Processing Facility, the first of three Space Shuttle Main Engines (SSME) is seen after installation. Discovery is the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

KSC-04PD-2510

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Orbiter Processing Facility, technicians wait below while a Hyster lift moves the first of three Space Shuttle Main Engines (SSME) into position above for installation on Discovery, the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

KSC-04PD-2516

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In this closeup view, the first of three Space Shuttle Main Engines (SSME) is seen after installation on Discovery in the Orbiter Processing Facility. Discovery is the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

KSC-04PD-2514

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Orbiter Processing Facility, the Hyster lift backs away from the orbiter Discovery after placing a Space Shuttle Main Engine (SSME) into position for installation. Discovery is the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

KSC-04PD-2512

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Orbiter Processing Facility, a technician (lower right) watches from inside as a Space Shuttle Main Engine (SSME) on the Hyster lift is maneuvered into position on Discovery, the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

KSC-04PD-2509

NASA Technical Reports Server (NTRS)

2004-01-01

KENNEDY SPACE CENTER, FLA. In the Orbiter Processing Facility, Discovery waits as the first of three Space Shuttle Main Engines (SSME) moves into position for installation on Discovery, the vehicle designated for the Return to Flight mission STS-114. Overall, an SSME weighs approximately 7,000 pounds. An SSME operates at greater temperature extremes than any mechanical system in common use today. The liquid hydrogen fuel is -423 degrees Fahrenheit, the second coldest liquid on Earth. When the hydrogen is burned with liquid oxygen, the temperature in the engine's combustion chamber reaches +6000 degrees Fahrenheit -- that's higher than the boiling point of Iron. The maximum equivalent horsepower developed by the three SSMEs is just over 37 million horsepower. The energy released by the three SSMEs is equivalent to the output of 23 Hoover Dams.

SSME Key Operations Demonstration

NASA Technical Reports Server (NTRS)

Anderson, Brian; Bradley, Michael; Ives, Janet

1997-01-01

A Space Shuttle Main Engine (SSME) test program was conducted between August 1995 and May 1996 using the Technology Test Bed (TTB) Engine. SSTO vehicle studies have indicated that increases in the propulsion system operating range can save significant weight and cost at the vehicle level. This test program demonstrated the ability of the SSME to accommodate a wide variation in safe operating ranges and therefore its applicability to the SSTO mission. A total of eight tests were completed with four at Marshall Space Flight Center's Advanced Engine Test Facility and four at the Stennis Space Center (SSC) A-2 attitude test stand. Key demonstration objectives were: 1) Mainstage operation at 5.4 to 6.9 mixture ratio; 2) Nominal engine start with significantly reduced engine inlet pressures of 50 psia LOX and 38 psia fuel; and 3) Low power level operation at 17%, 22%, 27%, 40%, 45%, and 50% of Rated Power Level. Use of the highly instrumented TTB engine for this test series has afforded the opportunity to study in great detail engine system operation not possible with a standard SSME and has significantly contributed to a greater understanding of the capabilities of the SSME and liquid rocket engines in general.

SSME component assembly and life management expert system

NASA Technical Reports Server (NTRS)

Ali, M.; Dietz, W. E.; Ferber, H. J.

1989-01-01

The space shuttle utilizes several rocket engine systems, all of which must function with a high degree of reliability for successful mission completion. The space shuttle main engine (SSME) is by far the most complex of the rocket engine systems and is designed to be reusable. The reusability of spacecraft systems introduces many problems related to testing, reliability, and logistics. Components must be assembled from parts inventories in a manner which will most effectively utilize the available parts. Assembly must be scheduled to efficiently utilize available assembly benches while still maintaining flight schedules. Assembled components must be assigned to as many contiguous flights as possible, to minimize component changes. Each component must undergo a rigorous testing program prior to flight. In addition, testing and assembly of flight engines and components must be done in conjunction with the assembly and testing of developmental engines and components. The development, testing, manufacture, and flight assignments of the engine fleet involves the satisfaction of many logistical and operational requirements, subject to many constraints. The purpose of the SSME Component Assembly and Life Management Expert System (CALMES) is to assist the engine assembly and scheduling process, and to insure that these activities utilize available resources as efficiently as possible.

KSC-04pd1641

NASA Image and Video Library

2004-08-03

KENNEDY SPACE CENTER, FLA. - In the Space Shuttle Main Engine (SSME) Processing Facility, Boeing-Rocketdyne technicians prepare to move SSME 2058, the first SSME fully assembled at KSC. Move conductor Bob Brackett (on ladder) supervises the placement of a sling around the engine with the assistance of crane operator Joe Ferrante (center) and a technician. The engine will be lifted from its vertical work stand into a horizontal position in preparation for shipment to NASA’s Stennis Space Center in Mississippi to undergo a hot fire acceptance test. It is the first of five engines to be fully assembled on site to reach the desired number of 15 engines ready for launch at any given time in the Space Shuttle program. A Space Shuttle has three reusable main engines. Each is 14 feet long, weighs about 7,800 pounds, is seven-and-a-half feet in diameter at the end of its nozzle, and generates almost 400,000 pounds of thrust. Historically, SSMEs were assembled in Canoga Park, Calif., with post-flight inspections performed at KSC. Both functions were consolidated in February 2002. The Rocketdyne Propulsion and Power division of The Boeing Co. manufactures the engines for NASA.

Studies and analyses of the Space Shuttle Main Engine: SSME failure data review, diagnostic survey and SSME diagnostic evaluation

NASA Technical Reports Server (NTRS)

Glover, R. C.; Kelley, B. A.; Tischer, A. E.

1986-01-01

The results of a review of the Space Shuttle Main Engine (SSME) failure data for the period 1980 through 1983 are presented. The data was collected, evaluated, and ranked according to procedures established during this study. A number of conclusions and recommendations are made based upon this failure data review. The results of a state-of-the-art diagnostic survey are also presented. This survey covered a broad range of diagnostic sensors and techniques and the findings were evaluated for application to the SSME. Finally, a discussion of the initial activities for the on-going SSME diagnostic evaluation is included.

SSME leak detection feasibility investigation by utilization of infrared sensor technology

NASA Technical Reports Server (NTRS)

Shohadaee, Ahmad A.; Crawford, Roger A.

1990-01-01

This investigation examined the potential of using state-of-the-art technology of infrared (IR) thermal imaging systems combined with computer, digital image processing and expert systems for Space Shuttle Main Engines (SSME) propellant path peak detection as an early warning system of imminent engine failure. A low-cost, laboratory experiment was devised and an experimental approach was established. The system was installed, checked out, and data were successfully acquired demonstrating the proof-of-concept. The conclusion from this investigation is that both numerical and experimental results indicate that the leak detection by using infrared sensor technology proved to be feasible for a rocket engine health monitoring system.

Study of weld offset in longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. S.; Brunair, R. M.

1992-01-01

Welded joints are an essential part of rocket engine structures such as the Space Shuttle Main Engine (SSME) turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet X-rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered in this report. Using the FEM and beamlike plate approximations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thicknesses on both sides of the joint. Following the study, some conclusions are derived for the weld offsets.

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

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

Application of advanced coating techniques to rocket engine components

NASA Technical Reports Server (NTRS)

Verma, S. K.

1988-01-01

The materials problem in the space shuttle main engine (SSME) is reviewed. Potential coatings and the method of their application for improved life of SSME components are discussed. A number of advanced coatings for turbine blade components and disks are being developed and tested in a multispecimen thermal fatigue fluidized bed facility at IIT Research Institute. This facility is capable of producing severe strains of the degree present in blades and disk components of the SSME. The potential coating systems and current efforts at IITRI being taken for life extension of the SSME components are summarized.

Characterization of real gas properties for space shuttle main engine fuel turbine and performance calculations

NASA Technical Reports Server (NTRS)

Harloff, G. J.

1986-01-01

Real thermodynamic and transport properties of hydrogen, steam, the SSME mixture, and air are developed. The SSME mixture properties are needed for the analysis of the space shuttle main engine fuel turbine. The mixture conditions for the gases, except air, are presented graphically over a temperature range from 800 to 1200 K, and a pressure range from 1 to 500 atm. Air properties are given over a temperature range of 320 to 500 K, which are within the bounds of the thermodynamics programs used, in order to provide mixture data which is more easily checked (than H2/H2O). The real gas property variation of the SSME mixture is quantified. Polynomial expressions, needed for future computer analysis, for viscosity, Prandtl number, and thermal conductivity are given for the H2/H2O SSME fuel turbine mixture at a pressure of 305 atm over a range of temperatures from 950 to 1140 K. These conditions are representative of the SSME turbine operation. Performance calculations are presented for the space shuttle main engine (SSME) fuel turbine. The calculations use the air equivalent concept. Progress towards obtaining the capability to evaluate the performance of the SSME fuel turbine, with the H2/H2O mixture, is described.

Radial basis function neural networks applied to NASA SSME data

NASA Technical Reports Server (NTRS)

Wheeler, Kevin R.; Dhawan, Atam P.

1993-01-01

This paper presents a brief report on the application of Radial Basis Function Neural Networks (RBFNN) to the prediction of sensor values for fault detection and diagnosis of the Space Shuttle's Main Engines (SSME). The location of the Radial Basis Function (RBF) node centers was determined with a K-means clustering algorithm. A neighborhood operation about these center points was used to determine the variances of the individual processing notes.

Thin-film sensors for space propulsion technology: Fabrication and preparation for testing

NASA Technical Reports Server (NTRS)

Kim, Walter S.; Hepp, Aloysius F.

1989-01-01

The goal of this work is to develop and test thin-film thermocouples for Space Shuttle Main Engine (SSME) components. Thin-film thermocouples have been developed for aircraft gas turbine engines and are in use for temperature measurement on turbine blades up to 1800 F. Established aircraft engine gas turbine technology is currently being adapted to turbine engine blade materials and the environment encountered in the SSME, especially severe thermal shock from cryogenic fuel to combustion temperatures. Initial results using coupons of MAR M-246 (+Hf) and PWA 1480 have been followed by fabrication of thin-film thermocouples on SSME turbine blades. Current efforts are focused on preparing for testing in the Turbine Blade Tester at the NASA Marshall Space Flight Center (MSFC). Future work will include testing of thin-film thermocouples on SSME blades of single crystal PWA 1480 at MSFC.

Health management system for rocket engines

NASA Technical Reports Server (NTRS)

Nemeth, Edward

1990-01-01

The functional framework of a failure detection algorithm for the Space Shuttle Main Engine (SSME) is developed. The basic algorithm is based only on existing SSME measurements. Supplemental measurements, expected to enhance failure detection effectiveness, are identified. To support the algorithm development, a figure of merit is defined to estimate the likelihood of SSME criticality 1 failure modes and the failure modes are ranked in order of likelihood of occurrence. Nine classes of failure detection strategies are evaluated and promising features are extracted as the basis for the failure detection algorithm. The failure detection algorithm provides early warning capabilities for a wide variety of SSME failure modes. Preliminary algorithm evaluation, using data from three SSME failures representing three different failure types, demonstrated indications of imminent catastrophic failure well in advance of redline cutoff in all three cases.

SSME Advanced Health Management: Project Overview

NASA Technical Reports Server (NTRS)

Plowden, John

2000-01-01

This document is the viewgraphs from a presentation concerning the development of the Health Management system for the Space Shuttle Main Engine (SSME). It reviews the historical background of the SSME Advanced Health Management effort through the present final Health management configuration. The document includes reviews of three subsystems to the Advanced Health Management System: (1) the Real-Time Vibration Monitor System, (2) the Linear Engine Model, and (3) the Optical Plume Anomaly Detection system.

Reusable rocket engine intelligent control system framework design, phase 2

NASA Technical Reports Server (NTRS)

Nemeth, ED; Anderson, Ron; Ols, Joe; Olsasky, Mark

1991-01-01

Elements of an advanced functional framework for reusable rocket engine propulsion system control are presented for the Space Shuttle Main Engine (SSME) demonstration case. Functional elements of the baseline functional framework are defined in detail. The SSME failure modes are evaluated and specific failure modes identified for inclusion in the advanced functional framework diagnostic system. Active control of the SSME start transient is investigated, leading to the identification of a promising approach to mitigating start transient excursions. Key elements of the functional framework are simulated and demonstration cases are provided. Finally, the advanced function framework for control of reusable rocket engines is presented.

SSME HPOTP post-test diagnostic system enhancement project

NASA Technical Reports Server (NTRS)

Bickmore, Timothy W.

1995-01-01

An assessment of engine and component health is routinely made after each test or flight firing of a space shuttle main engine (SSME). Currently, this health assessment is done by teams of engineers who manually review sensor data, performance data, and engine and component operating histories. Based on review of information from these various sources, an evaluation is made as to the health of each component of the SSME and the preparedness of the engine for another test or flight. The objective of this project is to further develop a computer program which automates the analysis of test data from the SSME high-pressure oxidizer turbopump (HPOTP) in order to detect and diagnose anomalies. This program fits into a larger system, the SSME Post-Test Diagnostic System (PTDS), which will eventually be extended to assess the health and status of most SSME components on the basis of test data analysis. The HPOTP module is an expert system, which uses 'rules-of-thumb' obtained from interviews with experts from NASA Marshall Space Flight Center (MSFC) to detect and diagnose anomalies. Analyses of the raw test data are first performed using pattern recognition techniques which result in features such as spikes, shifts, peaks, and drifts being detected and written to a database. The HPOTP module then looks for combination of these features which are indicative of known anomalies, using the rules gathered from the turbomachinery experts. Results of this analysis are then displayed via a graphical user interface which provides ranked lists of anomalies and observations by engine component, along with supporting data plots for each.

Specialized data analysis for the Space Shuttle Main Engine and diagnostic evaluation of advanced propulsion system components

NASA Technical Reports Server (NTRS)

1993-01-01

The Marshall Space Flight Center is responsible for the development and management of advanced launch vehicle propulsion systems, including the Space Shuttle Main Engine (SSME), which is presently operational, and the Space Transportation Main Engine (STME) under development. The SSME's provide high performance within stringent constraints on size, weight, and reliability. Based on operational experience, continuous design improvement is in progress to enhance system durability and reliability. Specialized data analysis and interpretation is required in support of SSME and advanced propulsion system diagnostic evaluations. Comprehensive evaluation of the dynamic measurements obtained from test and flight operations is necessary to provide timely assessment of the vibrational characteristics indicating the operational status of turbomachinery and other critical engine components. Efficient performance of this effort is critical due to the significant impact of dynamic evaluation results on ground test and launch schedules, and requires direct familiarity with SSME and derivative systems, test data acquisition, and diagnostic software. Detailed analysis and evaluation of dynamic measurements obtained during SSME and advanced system ground test and flight operations was performed including analytical/statistical assessment of component dynamic behavior, and the development and implementation of analytical/statistical models to efficiently define nominal component dynamic characteristics, detect anomalous behavior, and assess machinery operational condition. In addition, the SSME and J-2 data will be applied to develop vibroacoustic environments for advanced propulsion system components, as required. This study will provide timely assessment of engine component operational status, identify probable causes of malfunction, and indicate feasible engineering solutions. This contract will be performed through accomplishment of negotiated task orders.

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.

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.

Rocket Science: The Shuttle's Main Engines, though Old, Are not Forgotten in the New Exploration Initiative

NASA Technical Reports Server (NTRS)

Covault, Craig

2005-01-01

The Space Shuttle Main Engine (SSME), developed 30 years ago, remains a strong candidate for use in the new Exploration Initiative as part of a shuttle-derived heavy-lift expendable booster. This is because the Boeing-Rocket- dyne man-rated SSME remains the most highly efficient liquid rocket engine ever developed. There are only enough parts for 12-15 existing SSMEs, however, so one NASA option is to reinitiate SSME production to use it as a throw-away, as opposed to a reusable, powerplant for NASA s new heavy-lift booster.

A History of Space Shuttle Main Engine (SSME) Redline Limits Management

NASA Technical Reports Server (NTRS)

Arnold, Thomas M.

2011-01-01

The Space Shuttle Main Engine (SSME) has several "redlines", which are operational limits designated to preclude a catastrophic shutdown of the SSME. The Space Shuttle Orbiter utilizes a combination of hardware and software to enable or disable the automated redline shutdown capability. The Space Shuttle is launched with the automated SSME redline limits enabled, but there are many scenarios which may result in the manual disabling of the software by the onboard crew. The operational philosophy for manually enabling and disabling the redline limits software has evolved continuously throughout the history of the Space Shuttle Program, due to events such as SSME hardware changes and updates to Space Shuttle contingency abort software. In this paper, the evolution of SSME redline limits management will be fully reviewed, including the operational scenarios which call for manual intervention, and the events that triggered changes to the philosophy. Following this review, improvements to the management of redline limits for future spacecraft will be proposed.

Application of Weibull analysis to SSME hardware

NASA Technical Reports Server (NTRS)

Gray, L. A. B.

1986-01-01

Generally, it has been documented that the wearing of engine parts forms a failure distribution which can be approximated by a function developed by Weibull. The purpose here is to examine to what extent the Weibull distribution approximates failure data for designated engine parts of the Space Shuttle Main Engine (SSME). The current testing certification requirements will be examined in order to establish confidence levels. An examination of the failure history of SSME parts/assemblies (turbine blades, main combustion chamber, or high pressure fuel pump first stage impellers) which are limited in usage by time or starts will be done by using updated Weibull techniques. Efforts will be made by the investigator to predict failure trends by using Weibull techniques for SSME parts (turbine temperature sensors, chamber pressure transducers, actuators, and controllers) which are not severely limited by time or starts.

SSME Electrical Harness and Cable Development and Evolution

NASA Technical Reports Server (NTRS)

Abrams, Russ; Heflin, Johnny; Burns, Bob; Camper, Scott J.; Hill, Arthur J.

2010-01-01

The Space Shuttle Main Engine (SSME) electrical harness and cable system consists of the various interconnecting devices necessary for operation of complex rocket engine functions. Thirty seven harnesses incorporate unique connectors, backshell adapters, conductors, insulation, shielding, and physical barriers for a long maintenance-free life while providing the means to satisfy performance requirements and to mitigate adverse environmental influences. The objective of this paper is to provide a description of the SSME electrical harness and cable designs as well as the development history and lessons learned.

Incorporating engine health monitoring capability into the SSME Block II controller

NASA Astrophysics Data System (ADS)

Clarke, James W.; Copa, Roderick J.

An account is given of the architecture of the SSME's Block II controller's architecture, its incorporation of smart input electronics (SIE), and the potential benefits of this technology in SSME health-monitoring capabilities. SIE allows the Block II controller to conduct its control functions while simultaneously furnishing the computational capabilities and sensor input interface for any newly defined health-monitoring functions. It is expected that the SIE technology may be directly transferred to any follow-on engine design.

SSME Condition Monitoring Using Neural Networks and Plume Spectral Signatures

NASA Technical Reports Server (NTRS)

Hopkins, Randall; Benzing, Daniel

1996-01-01

For a variety of reasons, condition monitoring of the Space Shuttle Main Engine (SSME) has become an important concern for both ground tests and in-flight operation. The complexities of the SSME suggest that active, real-time condition monitoring should be performed to avoid large-scale or catastrophic failure of the engine. In 1986, the SSME became the subject of a plume emission spectroscopy project at NASA's Marshall Space Flight Center (MSFC). Since then, plume emission spectroscopy has recorded many nominal tests and the qualitative spectral features of the SSME plume are now well established. Significant discoveries made with both wide-band and narrow-band plume emission spectroscopy systems led MSFC to develop the Optical Plume Anomaly Detection (OPAD) system. The OPAD system is designed to provide condition monitoring of the SSME during ground-level testing. The operational health of the engine is achieved through the acquisition of spectrally resolved plume emissions and the subsequent identification of abnormal emission levels in the plume indicative of engine erosion or component failure. Eventually, OPAD, or a derivative of the technology, could find its way on to an actual space vehicle and provide in-flight engine condition monitoring. This technology step, however, will require miniaturized hardware capable of processing plume spectral data in real-time. An objective of OPAD condition monitoring is to determine how much of an element is present in the SSME plume. The basic premise is that by knowing the element and its concentration, this could be related back to the health of components within the engine. For example, an abnormal amount of silver in the plume might signify increased wear or deterioration of a particular bearing in the engine. Once an anomaly is identified, the engine could be shut down before catastrophic failure occurs. Currently, element concentrations in the plume are determined iteratively with the help of a non-linear computer code called SPECTRA, developed at the USAF Arnold Engineering Development Center. Ostensibly, the code produces intensity versus wavelength plots (i.e., spectra) when inputs such as element concentrations, reaction temperature, and reaction pressure are provided. However, in order to provide a higher-level analysis, element concentration is not specified explicitly as an input. Instead, two quantum variables, number density and broadening parameter, are used. Past experience with OPAD data analysis has revealed that the region of primary interest in any SSME plume spectrum lies in the wavelength band of 3300 A to 4330 A. Experience has also revealed that some elements, such as iron, cobalt and nickel, cause multiple peaks over the chosen wavelength range whereas other elements (magnesium, for example) have a few, relatively isolated peaks in the chosen wavelength range. Iteration with SPECTRA as a part of OPAD data analysis is an incredibly labor intensive task and not one to be performed by hand. What is really needed is the "inverse" of the computer code but the mathematical model for the inverse mapping is tenuous at best. However, building generalized models based upon known input/output mappings while ignoring details of the governing physical model is possible using neural networks. Thus the objective of the research project described herein was to quickly and accurately predict combustion temperature and element concentrations (i.e., number density and broadening parameter) from a given spectrum using a neural network. In other words, a neural network had to be developed that would provide a generalized "inverse" of the computer code SPECTRA.

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.

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.

Parametric study in weld mismatch of longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. L.; Brunair, R. M.

1991-01-01

Welded joints are an essential part of pressure vessels such as the Space Shuttle Main Engine (SSME) Turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet x rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered. Using the finite element method and mathematical formulations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thickness on both sides of the joint. From the study, the finite element results and theoretical solutions are presented.

Turnaround Time Modeling for Conceptual Rocket Engines

NASA Technical Reports Server (NTRS)

Nix, Michael; Staton, Eric J.

2004-01-01

Recent years have brought about a paradigm shift within NASA and the Space Launch Community regarding the performance of conceptual design. Reliability, maintainability, supportability, and operability are no longer effects of design; they have moved to the forefront and are affecting design. A primary focus of this shift has been a planned decrease in vehicle turnaround time. Potentials for instituting this decrease include attacking the issues of removing, refurbishing, and replacing the engines after each flight. less, it is important to understand the operational affects of an engine on turnaround time, ground support personnel and equipment. One tool for visualizing this relationship involves the creation of a Discrete Event Simulation (DES). A DES model can be used to run a series of trade studies to determine if the engine is meeting its requirements, and, if not, what can be altered to bring it into compliance. Using DES, it is possible to look at the ways in which labor requirements, parallel maintenance versus serial maintenance, and maintenance scheduling affect the overall turnaround time. A detailed DES model of the Space Shuttle Main Engines (SSME) has been developed. Trades may be performed using the SSME Processing Model to see where maintenance bottlenecks occur, what the benefits (if any) are of increasing the numbers of personnel, or the number and location of facilities, in addition to trades previously mentioned, all with the goal of optimizing the operational turnaround time and minimizing operational cost. The SSME Processing Model was developed in such a way that it can easily be used as a foundation for developing DES models of other operational or developmental reusable engines. Performing a DES on a developmental engine during the conceptual phase makes it easier to affect the design and make changes to bring about a decrease in turnaround time and costs.

Vacuum application of thermal barrier plasma coatings

NASA Technical Reports Server (NTRS)

Holmes, R. R.; Mckechnie, T. N.

1988-01-01

Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator.

SSME structural dynamic model development

NASA Technical Reports Server (NTRS)

Foley, M. J.; Tilley, D. M.; Welch, C. T.

1983-01-01

A mathematical model of the Space Shuttle Main Engine (SSME) as a complete assembly, with detailed emphasis on LOX and High Fuel Turbopumps is developed. The advantages of both complete engine dynamics, and high fidelity modeling are incorporated. Development of this model, some results, and projected applications are discussed.

Incipient failure detection of space shuttle main engine turbopump bearings using vibration envelope detection

NASA Technical Reports Server (NTRS)

Hopson, Charles B.

1987-01-01

The results of an analysis performed on seven successive Space Shuttle Main Engine (SSME) static test firings, utilizing envelope detection of external accelerometer data are discussed. The results clearly show the great potential for using envelope detection techniques in SSME incipient failure detection.

Develop advanced nonlinear signal analysis topographical mapping system

NASA Technical Reports Server (NTRS)

Jong, Jen-Yi

1993-01-01

This study will provide timely assessment of SSME component operational status, identify probable causes of malfunction, and indicate feasible engineering solutions. The final result of this program will yield an advanced nonlinear signal analysis topographical mapping system (ATMS) of nonlinear and nonstationary spectral analysis software package integrated with the Compressed SSME TOPO Data Base (CSTDB) on the same platform. This system will allow NASA engineers to retrieve any unique defect signatures and trends associated with different failure modes and anomalous phenomena over the entire SSME test history across turbopump families.

Initially Researches for the Development of SSME under the Background of IOT

NASA Astrophysics Data System (ADS)

Han, Kun; Liu, Shurong; Zhang, Dacheng; Han, Ying

The Internet Of Things (IOT) is proposed in the 1990s. The original intention has been put forward is people to things and things to things can deliver information like person as. IOT broke the human traditional thinking. This paper researches the practical function of IOT to expand the theory of Services Sciences, Management and Engineering (SSME). On the analysis of the key technology and model of IOT, the events-driven SSME model based on IOT, and the IOT framework based on SSME, it further studies the importance of IOT in the field of SSME.

RS-25 for the NASA Cargo Launch Vehicle: The Evolution of SSME for Space Exploration

NASA Technical Reports Server (NTRS)

Kynard, Michael H.; McArthur, J. Craig; Ise, Dayna S.

2006-01-01

A key element of the National Vision for Space Exploration is the development of a heavy-lift Cargo Launch Vehicle (CaLV). Missions to the Moon, Mars, and beyond are only possible with the logistical capacity of putting large payloads in low-earth orbit. However, beyond simple logistics, there exists the need for this capability to be as cost effective as possible to ensure mission sustainability. An element of the CaLV project is, therefore, the development of the RS-25, which represents the evolution of the proven Space Shuttle Main Engine (SSME) into a high-performance, cost-effective expendable rocket engine. The development of the RS-25 will be built upon the foundation of over one million seconds of accumulated hot-fire time on the SSME. Yet in order to transform the reusable SSME into the more cost-effective, expendable RS-25 changes will have to be made. Thus the project will inevitably strive to maintain a balance between demonstrated heritage products and processes and the utilization of newer technology developments. Towards that end, the Core Stage Engine Office has been established at the NASA Marshall Space Flight Center to initiate the design and development of the RS-25 engine. This paper is being written very early in the formulation phase of the RS-25 project. Therefore the focus of this paper will be to present the scope, challenges, and opportunities for the RS-25 project. Early schedules and development decisions and plans will be explained. For not only must the RS-25 project achieve cost effectiveness through the development of new, evolved components such as a channel-wall nozzle, a new HIP-bonded main combustion chamber, and several others, it must simultaneously develop the means whereby this engine can be manufactured on a scale never envisioned for the SSME. Thus, while the overall project will span the next eight to ten years, there is little doubt that even this schedule is aggressive with a great deal of work to accomplish.

Space Shuttle Main Engine Low Pressure Oxidizer Turbo-Pump Inducer Dynamic Environment Characterization through Water Model and Hot-Fire Testing

NASA Technical Reports Server (NTRS)

Arellano, Patrick; Patton, Marc; Schwartz, Alan; Stanton, David

2006-01-01

The Low Pressure Oxidizer Turbopump (LPOTP) inducer on the Block II configuration Space Shuttle Main Engine (SSME) experienced blade leading edge ripples during hot firing. This undesirable condition led to a minor redesign of the inducer blades. This resulted in the need to evaluate the performance and the dynamic environment of the redesign, relative to the current configuration, as part of the design acceptance process. Sub-scale water model tests of the two inducer configurations were performed, with emphasis on the dynamic environment due to cavitation induced vibrations. Water model tests were performed over a wide range of inlet flow coefficient and pressure conditions, representative of the scaled operating envelope of the Block II SSME, both in flight and in ground hot-fire tests, including all power levels. The water test hardware, facility set-up, type and placement of instrumentation, the scope of the test program, specific test objectives, data evaluation process and water test results that characterize and compare the two SSME LPOTP inducers are discussed. In addition, dynamic characteristics of the two water models were compared to hot fire data from specially instrumented ground tests. In general, good agreement between the water model and hot fire data was found, which confirms the value of water model testing for dynamic characterization of rocket engine turbomachinery.

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.

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.

Tripropellant engine study

NASA Technical Reports Server (NTRS)

Wheeler, D. B.; Kirby, F. M.

1978-01-01

The potential for converting the space shuttle main engine (SSME) to a dual-fuel, dual-mode engine using LOX/hydrocarbon propellants in mode 1 and LOX/H2 in mode 2 was examined. Various engine system concepts were formulated that included staged combustion and gas generator turbine power cycles, and LOX/RP-1, LOX/CH4, and LOX/C3H8 mode 1 propellants. Both oxidizer and fuel regenerative cooling were considered. All of the SSME major components were examined to determine their adaptability to the candidate dual-fuel engines.

The Evolution of Utilizing Manual Throttles to Avoid Low LH2 NPSP at the SSME Inlet

NASA Technical Reports Server (NTRS)

Henfling, Rick

2011-01-01

Even before the first flight of the Space Shuttle, it was understood low liquid hydrogen (LH2) Net Positive Suction Pressure (NPSP) at the inlet to the Space Shuttle Main Engine (SSME) can have adverse effects on engine operation. A number of failures within both the External Tank (ET) and the Orbiter Main Propulsion System could result in a low LH2 NPSP condition. Operational workarounds were developed to take advantage of the onboard crew s ability to manually throttle down the SSMEs, which alleviated the low LH2 NPSP condition. A throttling down of the SSME resulted in an increase in NPSP, mainly due to the reduction in frictional flow losses while at a lower throttle setting. As engineers refined their understanding of the NPSP requirements for the SSME (through a robust testing program), the operational techniques evolved to take advantage of these additional capabilities. Currently the procedure, which for early Space Shuttle missions required a Return-to-Launch-Site abort, now would result in a nominal Main Engine Cut Off (MECO) and no loss of mission objectives.

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.

Emission spectra of selected SSME elements and materials

NASA Technical Reports Server (NTRS)

Tejwani, Gopal D.; Vandyke, David B.; Bircher, Felix E.; Gardner, Donald G.; Chenevert, Donald J.

1992-01-01

Stennis Space Center (SSC) is pursuing the advancement of experimental techniques and theoretical developments in the field of plume spectroscopy for application to rocket development testing programs and engine health monitoring. Exhaust plume spectral data for the Space Shuttle Main Engine (SSME) are routinely acquired. The usefulness of this data depends upon qualitative and quantitative interpretation of spectral features and their correlation with the engine performance. A knowledge of the emission spectral characteristics of effluent materials in the exhaust plume is essential. A study of SSME critical components and their materials identified 30 elements and 53 materials whose engine exhaust plume spectral might be required. The most important were evaluated using SSC's Diagnostic Testbed Facility Thruster (DTFT), a 1200-lbf, liquid oxygen/gaseous hydrogen rocket engine which very nearly replicates the temperature and pressure conditions of the SSME exhaust plume in the first Mach diamond. This report presents the spectral data for the 10 most important elements and 27 most important materials which are strongly to moderately emitting in the DTFT exhaust plume. The covered spectral range is 300 to 426 nm and the spectral resolution is 0.25 nm. Spectral line identification information is provided and line interference effects are considered.

Fluctuating Pressure Analysis of a 2-D SSME Nozzle Air Flow Test

NASA Technical Reports Server (NTRS)

Reed, Darren; Hidalgo, Homero

1996-01-01

To better understand the Space Shuttle Main Engine (SSME) startup/shutdown tansients, an airflow test of a two dimensional nozzle was conducted at Marshall Space Flight Center's trisonic wind tunnel. Photographic and other instrumentation show during an SSME start large nozzle shell distortions occur as the Mach disk is passing through the nozzle. During earlier develop of the SSME, this startup transient resulted in low cycle fatigue failure of one of the LH2 feedlines. The two dimensional SSME nozzle test was designed to measure the static and fluctuating pressure environment and color Schlieren video during the startup and shutdown phases of the run profile.

Nonlinear heat transfer and structural analyses of SSME turbine blades

NASA Technical Reports Server (NTRS)

Abdul-Aziz, A.; Kaufman, A.

1987-01-01

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

Digital filtering of plume emission spectra

NASA Technical Reports Server (NTRS)

Madzsar, George C.

1990-01-01

Fourier transformation and digital filtering techniques were used to separate the superpositioned spectral phenomena observed in the exhaust plumes of liquid propellant rocket engines. Space shuttle main engine (SSME) spectral data were used to show that extraction of spectral lines in the spatial frequency domain does not introduce error, and extraction of the background continuum introduces only minimal error. Error introduced during band extraction could not be quantified due to poor spectrometer resolution. Based on the atomic and molecular species found in the SSME plume, it was determined that spectrometer resolution must be 0.03 nm for SSME plume spectral monitoring.

Develop advanced nonlinear signal analysis topographical mapping system

NASA Technical Reports Server (NTRS)

1994-01-01

The Space Shuttle Main Engine (SSME) has been undergoing extensive flight certification and developmental testing, which involves some 250 health monitoring measurements. Under the severe temperature, pressure, and dynamic environments sustained during operation, numerous major component failures have occurred, resulting in extensive engine hardware damage and scheduling losses. To enhance SSME safety and reliability, detailed analysis and evaluation of the measurements signal are mandatory to assess its dynamic characteristics and operational condition. Efficient and reliable signal detection techniques will reduce catastrophic system failure risks and expedite the evaluation of both flight and ground test data, and thereby reduce launch turn-around time. The basic objective of this contract are threefold: (1) develop and validate a hierarchy of innovative signal analysis techniques for nonlinear and nonstationary time-frequency analysis. Performance evaluation will be carried out through detailed analysis of extensive SSME static firing and flight data. These techniques will be incorporated into a fully automated system; (2) develop an advanced nonlinear signal analysis topographical mapping system (ATMS) to generate a Compressed SSME TOPO Data Base (CSTDB). This ATMS system will convert tremendous amount of complex vibration signals from the entire SSME test history into a bank of succinct image-like patterns while retaining all respective phase information. High compression ratio can be achieved to allow minimal storage requirement, while providing fast signature retrieval, pattern comparison, and identification capabilities; and (3) integrate the nonlinear correlation techniques into the CSTDB data base with compatible TOPO input data format. Such integrated ATMS system will provide the large test archives necessary for quick signature comparison. This study will provide timely assessment of SSME component operational status, identify probable causes of malfunction, and indicate feasible engineering solutions. The final result of this program will yield an ATMS system of nonlinear and nonstationary spectral analysis software package integrated with the Compressed SSME TOPO Data Base (CSTDB) on the same platform. This system will allow NASA engineers to retrieve any unique defect signatures and trends associated with different failure modes and anomalous phenomena over the entire SSME test history across turbo pump families.

Operational Issues in the Development of a Cost-Effective Reusable LOX/LH2 Engine

NASA Technical Reports Server (NTRS)

Ballard, Richard O.

2003-01-01

The NASA Space Launch Initiative (SLI) was initiated in early 2001 to conduct technology development and to reduce the business and technical risk associated with developing the next-generation reusable launch system. In the field of main propulsion, two LOXLH2 rocket engine systems, the Pratt & Whitney / Aerojet Joint Venture (JV) COBRA and the Rocketdyne RS-83, were funded to develop a safe, economical, and reusable propulsion system. Given that a large-thrust reusable rocket engine program had not been started in the U.S. since 1971, with the Space Shuttle Main Engine (SSME), this provided an opportunity to build on the experience developed on the SSME system, while exploiting advances in technology that had occurred in the intervening 30 years. One facet of engine development that was identified as being especially vital in order to produce an optimal system was in the areas of operability and maintainability. In order to achieve the high levels of performance required by the Space Shuttle, the SSME system is highly complex with very tight tolerances and detailed requirements. Over the lifetime of the SSME program, the engine has required a high level of manpower to support the performance of inspections, maintenance (scheduled and unscheduled) and operations (prelaunch and post-flight). As a consequence, the labor- intensive needs of the SSME provide a significant impact to the overall cost efficiency of the Space Transportation System (STS). One of the strategic goals of the SLI is to reduce cost by requiring the engine(s) to be easier (Le. less expensive) to operate and maintain. The most effective means of accomplishing this goal is to infuse the operability and maintainability features into the engine design from the start. This paper discusses some of the operational issues relevant to a reusable LOx/LH2 main engine, and the means by which their impact is mitigated in the design phase.

Vibration, acoustic, and shock design and test criteria for components on the Solid Rocket Boosters (SRB), Lightweight External Tank (LWT), and Space Shuttle Main Engines (SSME)

NASA Technical Reports Server (NTRS)

1984-01-01

The vibration, acoustics, and shock design and test criteria for components and subassemblies on the space shuttle solid rocket booster (SRB), lightweight tank (LWT), and main engines (SSME) are presented. Specifications for transportation, handling, and acceptance testing are also provided.

Specialized data analysis of SSME and advanced propulsion system vibration measurements

NASA Technical Reports Server (NTRS)

Coffin, Thomas; Swanson, Wayne L.; Jong, Yen-Yi

1993-01-01

The basic objectives of this contract were to perform detailed analysis and evaluation of dynamic data obtained during Space Shuttle Main Engine (SSME) test and flight operations, including analytical/statistical assessment of component dynamic performance, and to continue the development and implementation of analytical/statistical models to effectively define nominal component dynamic characteristics, detect anomalous behavior, and assess machinery operational conditions. This study was to provide timely assessment of engine component operational status, identify probable causes of malfunction, and define feasible engineering solutions. The work was performed under three broad tasks: (1) Analysis, Evaluation, and Documentation of SSME Dynamic Test Results; (2) Data Base and Analytical Model Development and Application; and (3) Development and Application of Vibration Signature Analysis Techniques.

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.

Automated Propulsion Data Screening demonstration system

NASA Technical Reports Server (NTRS)

Hoyt, W. Andes; Choate, Timothy D.; Whitehead, Bruce A.

1995-01-01

A fully-instrumented firing of a propulsion system typically generates a very large quantity of data. In the case of the Space Shuttle Main Engine (SSME), data analysis from ground tests and flights is currently a labor-intensive process. Human experts spend a great deal of time examining the large volume of sensor data generated by each engine firing. These experts look for any anomalies in the data which might indicate engine conditions warranting further investigation. The contract effort was to develop a 'first-cut' screening system for application to SSME engine firings that would identify the relatively small volume of data which is unusual or anomalous in some way. With such a system, limited and expensive human resources could focus on this small volume of unusual data for thorough analysis. The overall project objective was to develop a fully operational Automated Propulsion Data Screening (APDS) system with the capability of detecting significant trends and anomalies in transient and steady-state data. However, the effort limited screening of transient data to ground test data for throttle-down cases typical of the 3-g acceleration, and for engine throttling required to reach the maximum dynamic pressure limits imposed on the Space Shuttle. This APDS is based on neural networks designed to detect anomalies in propulsion system data that are not part of the data used for neural network training. The delivered system allows engineers to build their own screening sets for application to completed or planned firings of the SSME. ERC developers also built some generic screening sets that NASA engineers could apply immediately to their data analysis efforts.

Research pressure instrumentation for NASA space shuttle main engine

NASA Technical Reports Server (NTRS)

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

1985-01-01

The breadboard feasibility model of a silicon piezoresistive pressure transducer suitable for space shuttle main engine (SSME) applications was demonstrated. The development of pressure instrumentation for the SSME was examined. The objective is to develop prototype pressure transducers which are targeted to meet the SSME performance design goals and to fabricate, test and deliver a total of 10 prototype units. Effective utilization of the many advantages of silicon piezoresistive strain sensing technology to achieve the objectives of advanced state-of-the-art pressure sensors for reliability, accuracy and ease of manufacture is analyzed. Integration of multiple functions on a single chip is the key attribute of the technology.

Evolutionary Development of the Simulation by Logical Modeling System (SIBYL)

NASA Technical Reports Server (NTRS)

Wu, Helen

1995-01-01

Through the evolutionary development of the Simulation by Logical Modeling System (SIBYL) we have re-engineered the expensive and complex IBM mainframe based Long-term Hardware Projection Model (LHPM) to a robust cost-effective computer based mode that is easy to use. We achieved significant cost reductions and improved productivity in preparing long-term forecasts of Space Shuttle Main Engine (SSME) hardware. The LHPM for the SSME is a stochastic simulation model that projects the hardware requirements over 10 years. SIBYL is now the primary modeling tool for developing SSME logistics proposals and Program Operating Plan (POP) for NASA and divisional marketing studies.

Development of life prediction capabilities for liquid propellant rocket engines. Post-fire diagnostic system for the SSME system architecture study

NASA Technical Reports Server (NTRS)

Gage, Mark; Dehoff, Ronald

1991-01-01

This system architecture task (1) analyzed the current process used to make an assessment of engine and component health after each test or flight firing of an SSME, (2) developed an approach and a specific set of objectives and requirements for automated diagnostics during post fire health assessment, and (3) listed and described the software applications required to implement this system. The diagnostic system described is a distributed system with a database management system to store diagnostic information and test data, a CAE package for visual data analysis and preparation of plots of hot-fire data, a set of procedural applications for routine anomaly detection, and an expert system for the advanced anomaly detection and evaluation.

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.

Thin film thermocouples for high temperature turbine application

NASA Technical Reports Server (NTRS)

Martin, Lisa C.

1991-01-01

The objective is to develop thin film thermocouples (TFTC) for Space Shuttle Main Engine (SSME) components such as the high pressure fuel turbopump (HPFTP) blades and to test TFTC survivability and durability in the SSME environment. The purpose for developing TFTC's for SSME components is to obtain blade temperatures for computational models developed for fluid mechanics and structures. The TFTC must be able to withstand the presence of high temperature, high pressure hydrogen as well as a severe thermal transient due to a cryogenic to combustion temperature change. The TFTC's will eventually be installed and tested on SSME propulsion system components in the SSME test bed engine. The TFTC's were successfully fabricated on flat coupons of MAR-M 246 (Hf+), which is the superalloy material used for HPFTP turbine blades. The TFTC's fabricated on flat coupons survived thermal shock cycling as well as testing in a heat flux measurement facility which provided a rapid thermal transient. The same fabrication procedure was used to deposit TFTC's on HPFTP first stage rotor blades. Other results from the experiments are presented, and future testing plans are discussed.

Advanced Transportation System Studies. Technical Area 3: Alternate Propulsion Subsystem Concepts. Volume 1; Executive Summary

NASA Technical Reports Server (NTRS)

Levack, Daniel J. H.

2000-01-01

The Alternate Propulsion Subsystem Concepts contract had seven tasks defined that are reported under this contract deliverable. The tasks were: FAA Restart Study, J-2S Restart Study, Propulsion Database Development. SSME Upper Stage Use. CERs for Liquid Propellant Rocket Engines. Advanced Low Cost Engines, and Tripropellant Comparison Study. The two restart studies, F-1A and J-2S, generated program plans for restarting production of each engine. Special emphasis was placed on determining changes to individual parts due to obsolete materials, changes in OSHA and environmental concerns, new processes available, and any configuration changes to the engines. The Propulsion Database Development task developed a database structure and format which is easy to use and modify while also being comprehensive in the level of detail available. The database structure included extensive engine information and allows for parametric data generation for conceptual engine concepts. The SSME Upper Stage Use task examined the changes needed or desirable to use the SSME as an upper stage engine both in a second stage and in a translunar injection stage. The CERs for Liquid Engines task developed qualitative parametric cost estimating relationships at the engine and major subassembly level for estimating development and production costs of chemical propulsion liquid rocket engines. The Advanced Low Cost Engines task examined propulsion systems for SSTO applications including engine concept definition, mission analysis. trade studies. operating point selection, turbomachinery alternatives, life cycle cost, weight definition. and point design conceptual drawings and component design. The task concentrated on bipropellant engines, but also examined tripropellant engines. The Tripropellant Comparison Study task provided an unambiguous comparison among various tripropellant implementation approaches and cycle choices, and then compared them to similarly designed bipropellant engines in the SSTO mission This volume overviews each of the tasks giving its objectives, main results. and conclusions. More detailed Final Task Reports are available on each individual task.

Faces of SSME

NASA Technical Reports Server (NTRS)

2009-01-01

Several employees who contributed to the Space Shuttle Main Engine (SSME) program describe their most memorable experiences relating to the launching of the Space Shuttle. Some describe the emotional aspects they experienced while watching and filming the launch from Kennedy Space Center.

Remtech SSME nozzle design TPS

NASA Technical Reports Server (NTRS)

Bancroft, Steven A.; Engel, Carl D.; Pond, John E.

1990-01-01

Thermal damage to the Space Shuttle Main Engine (SSME) aft manifold Thermal Protection System (TPS) has been observed for flights STS-8 through STS-13. This damaged area is located on the ME2 and ME3 and extends over a region of approximately one square foot. Total failure or burn-through of the TPS could lead to severe thermal damage of the SSME manifold and loss of an engine nozzle necessitating nozzle replacement causing significant schedule delays and cost increases. Thermal damage to the manifold can be defined as a situation where the manifold temperature becomes greater than 1300 F; thereby causing loss of heat treatment in the nozzle. Results of Orbiter/nozzle wind tunnel tests and Hot Gas Facility tests of the TPS are presented. Aerothermal and thermal analysis models for the SSME aft manifold are discussed along with the flight predictions, design trajectory and design environment. Finally, the TPS design concept and TPS thermal response are addressed.

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.

Return to flight SSME test at A2 test stand

NASA Image and Video Library

2004-07-16

The Space Shuttle Main Engine (SSME) reached a historic milestone July 16, 2004, when a successful flight acceptance test was conducted at NASA Stennis Space Center (SSC). The engine tested today is the first complete engine to be tested and shipped in its entirety to Kennedy Space Center for installation on Space Shuttle Discovery for STS-114, NASA's Return to Flight mission. The engine test, which began about 3:59 p.m. CDT, ran for 520 seconds (8 minutes), the length of time it takes for the Space Shuttle to reach orbit.

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.

Orbiter Atlantis (STS-110) Launch With New Block II Engines

NASA Technical Reports Server (NTRS)

2002-01-01

Powered by three newly-enhanced Space Shuttle Maine Engines (SSMEs), called the Block II Maine Engines, the Space Shuttle Orbiter Atlantis lifted off from the Kennedy Space Center launch pad on April 8, 2002 for the STS-110 mission. The Block II Main Engines incorporate an improved fuel pump featuring fewer welds, a stronger integral shaft/disk, and more robust bearings, making them safer and more reliable, and potentially increasing the number of flights between major overhauls. NASA continues to increase the reliability and safety of Shuttle flights through a series of enhancements to the SSME. The engines were modified in 1988 and 1995. Developed in the 1970s and managed by the Space Shuttle Projects Office at the Marshall Space Flight Center, the SSME is the world's most sophisticated reusable rocket engine. The new turbopump made by Pratt and Whitney of West Palm Beach, Florida, was tested at NASA's Stennis Space Center in Mississippi. Boeing Rocketdyne in Canoga Park, California, manufactures the SSME. This image was extracted from engineering motion picture footage taken by a tracking camera.

Space Shuttle Main Engine Public Test Firing

NASA Image and Video Library

2000-07-25

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.

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

NASA Technical Reports Server (NTRS)

Sander, Erik J.; Gosdin, Dennis R.

1992-01-01

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.

Develop advanced nonlinear signal analysis topographical mapping system

NASA Technical Reports Server (NTRS)

Jong, Jen-Yi

1993-01-01

The SSME has been undergoing extensive flight certification and developmental testing, which involves some 250 health monitoring measurements. Under the severe temperature pressure, and dynamic environments sustained during operation, numerous major component failures have occurred, resulting in extensive engine hardware damage and scheduling losses. To enhance SSME safety and reliability, detailed analysis and evaluation of the measurements signal are mandatory to assess its dynamic characteristics and operational condition. Efficient and reliable signal detection techniques will reduce catastrophic system failure risks and expedite the evaluation of both flight and ground test data, and thereby reduce launch turn-around time. The basic objective of this contract are threefold: (1) Develop and validate a hierarchy of innovative signal analysis techniques for nonlinear and nonstationary time-frequency analysis. Performance evaluation will be carried out through detailed analysis of extensive SSME static firing and flight data. These techniques will be incorporated into a fully automated system. (2) Develop an advanced nonlinear signal analysis topographical mapping system (ATMS) to generate a Compressed SSME TOPO Data Base (CSTDB). This ATMS system will convert tremendous amounts of complex vibration signals from the entire SSME test history into a bank of succinct image-like patterns while retaining all respective phase information. A high compression ratio can be achieved to allow the minimal storage requirement, while providing fast signature retrieval, pattern comparison, and identification capabilities. (3) Integrate the nonlinear correlation techniques into the CSTDB data base with compatible TOPO input data format. Such integrated ATMS system will provide the large test archives necessary for a quick signature comparison. This study will provide timely assessment of SSME component operational status, identify probable causes of malfunction, and indicate feasible engineering solutions. The final result of this program will yield an ATMS system of nonlinear and nonstationary spectral analysis software package integrated with the Compressed SSME TOPO Data Base (CSTDB) on the same platform. This system will allow NASA engineers to retrieve any unique defect signatures and trends associated with different failure modes and anomalous phenomena over the entire SSME test history across turbo pump families.

Time-Dependent Simulations of Incompressible Flow in a Turbopump Using Overset Grid Approach

NASA Technical Reports Server (NTRS)

Kiris, Cetin; Kwak, Dochan

2001-01-01

This viewgraph presentation provides information on mathematical modelling of the SSME (space shuttle main engine). The unsteady SSME-rig1 start-up procedure from the pump at rest has been initiated by using 34.3 million grid points. The computational model for the SSME-rig1 has been completed. Moving boundary capability is obtained by using DCF module in OVERFLOW-D. MPI (Message Passing Interface)/OpenMP hybrid parallel code has been benchmarked.

Thin-film sensors for reusable space propulsion systems

NASA Technical Reports Server (NTRS)

Hepp, Aloysius F.; Kim, Walter S.

1989-01-01

Thin-film thermocouples (TFTCs) were developed for aircraft gas turbine engines and are in use for temperature measurement on turbine blades up to 1800 F. Established aircraft engine gas turbine technology is currently being adapted to turbine engine blade materials and the environment encountered in the Space Shuttle Main Engine (SSME)-severe thermal shock from cryogenic fuel to combustion temperatures. Initial results with coupons of MAR M-246 (+Hf) and PWA 1480 were followed by fabrication of TFTC on SSME turbine blades. Current efforts are focused on preparation for testing in the Turbine Blade Tester at NASA Marshall Space Flight Center.

SSME environment database development

NASA Technical Reports Server (NTRS)

Reardon, John

1987-01-01

The internal environment of the Space Shuttle Main Engine (SSME) is being determined from hot firings of the prototype engines and from model tests using either air or water as the test fluid. The objectives are to develop a database system to facilitate management and analysis of test measurements and results, to enter available data into the the database, and to analyze available data to establish conventions and procedures to provide consistency in data normalization and configuration geometry references.

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.

X-ray spectroscopy of the SSME plume

NASA Technical Reports Server (NTRS)

Olive, Dan F.

1988-01-01

In order to examine the potential of using SSME exhaust plume radiation in the soft X-ray spectrum as an early warning system of imminent engine failure, a low cost, low risk experiment was devised. An approach was established, equipment was leased, the system was installed and checked out, and data were successfully acquired demonstrating the proof-of-concept. One spectrum measurement of the SSME plume was acquired during a 300 second burn on the A-1 Test Stand. This spectrum showed a prominent, line emission feature at about 34.5 KeV, a result which was not expected, nor can it be explained at this time. If X-ray spectra are to be useful as a means of monitoring nominal engine operation, it will be necessary to explore this region of the EM spectrum in greater detail. The presence of structure in the spectrum indicates that this technology may prove to be useful as an engine health monitoring system.

Flow dynamic environment data base development for the SSME

NASA Technical Reports Server (NTRS)

Sundaram, C. V.

1985-01-01

The fluid flow-induced vibration of the Space Shuttle main engine (SSME) components are being studied with a view to correlating the frequency characteristics of the pressure fluctuations in a rocket engine to its operating conditions and geometry. An overview of the data base development for SSME test firing results and the interactive computer software used to access, retrieve, and plot or print the results selectively for given thrust levels, engine numbers, etc., is presented. The various statistical methods available in the computer code for data analysis are discussed. Plots of test data, nondimensionalized using parameters such as fluid flow velocities, densities, and pressures, are presented. Results are compared with those available in the literature. Correlations between the resonant peaks observed at higher frequencies in power spectral density plots with pump geometry and operating conditions are discussed. An overview of the status of the investigation is presented and future directions are discussed.

Space Shuttle Propulsion System Reliability

NASA Technical Reports Server (NTRS)

Welzyn, Ken; VanHooser, Katherine; Moore, Dennis; Wood, David

2011-01-01

This session includes the following sessions: (1) External Tank (ET) System Reliability and Lessons, (2) Space Shuttle Main Engine (SSME), Reliability Validated by a Million Seconds of Testing, (3) Reusable Solid Rocket Motor (RSRM) Reliability via Process Control, and (4) Solid Rocket Booster (SRB) Reliability via Acceptance and Testing.

Programs for Testing an SSME-Monitoring System

NASA Technical Reports Server (NTRS)

Lang, Andre; Cecil, Jimmie; Heusinger, Ralph; Freestone, Kathleen; Blue, Lisa; Wilkerson, DeLisa; McMahon, Leigh Anne; Hall, Richard B.; Varnavas, Kosta; Smith, Keary;

Redesign and Test of an SSME Turbopump for the Large Throat Main Combustion Chamber

NASA Technical Reports Server (NTRS)

Lunde, K. J.; Lee, G. A.; Eastland, A. H.; Rojas, L.

1994-01-01

The preburner oxidizer turbopump for the Space Shuttle Main Engine (SSME) was successfully redesigned for use with the Large Throat Main Combustion Chamber (LTMCC) and tested in air utilizing rapid prototyping. The redesign increases the SSME's operating range with the current Main Combustion Chamber (MCC) while achieving full operational range with the LTMCC. The use of rapid prototyping and air testing to validate the redesign demonstrated the ability to design, fabricate and test designs rapidly and at a very low cost.

STS-51 pad abort. OV103-engine 2033 (ME-2) fuel flowmeter sensor open circuit

NASA Technical Reports Server (NTRS)

1993-01-01

The STS-51 initial launch attempt of Discovery (OV-103) was terminated on KSC launch pad 39B on 12 Aug. 1993 at 9:12 AM E.S.T. due to a sensor redundancy failure in the liquid hydrogen system of ME-2 (Engine 2033). The event description and time line are summarized. Propellant loading was initiated on 12 Aug. 1993 at 12:00 AM EST. All space shuttle main engine (SSME) chill parameters and Launch Commit Criteria (LCC) were nominal. At engine start plus 1.34 seconds a Failure Identification (FID) was posted against Engine 2033 for exceeding the 1800 spin intra-channel (A1-A2) Fuel Flowrate sensor channel qualification limit. The engine was shut down at 1.50 seconds followed by Engines 2032 and 2030. All shut down sequences were nominal and the mission was safely aborted. SSME Avionics hardware and software performed nominally during the incident. A review of vehicle data table (VDT) data and controller software logic revealed no failure indications other than the single FID 111-101, Fuel Flowrate Intra-Channel Test Channel A disqualification. Software logic was executed according to requirements and there was no anomalous controller software operation. Immediately following the abort, a Rocketdyne/NASA failure investigation team was assembled. The team successfully isolated the failure cause to an open circuit in a Fuel Flowrate Sensor. This type of failure has occurred eight previous times in ground testing. The sensor had performed acceptably on three previous flights of the engine and SSME flight history shows 684 combined fuel flow rate sensor channel flights without failure. The disqualification of an Engine 2 (SSME No. 2033) Fuel Flowrate sensor channel was a result of an instrumentation failure and not engine performance. All other engine operations were nominal. This disqualification resulted in an engine shutdown and safe sequential shutdown of all three engines prior to ignition of the solid boosters.

NASA Applications and Lessons Learned in Reliability Engineering

NASA Technical Reports Server (NTRS)

Safie, Fayssal M.; Fuller, Raymond P.

2011-01-01

Since the Shuttle Challenger accident in 1986, communities across NASA have been developing and extensively using quantitative reliability and risk assessment methods in their decision making process. This paper discusses several reliability engineering applications that NASA has used over the year to support the design, development, and operation of critical space flight hardware. Specifically, the paper discusses several reliability engineering applications used by NASA in areas such as risk management, inspection policies, components upgrades, reliability growth, integrated failure analysis, and physics based probabilistic engineering analysis. In each of these areas, the paper provides a brief discussion of a case study to demonstrate the value added and the criticality of reliability engineering in supporting NASA project and program decisions to fly safely. Examples of these case studies discussed are reliability based life limit extension of Shuttle Space Main Engine (SSME) hardware, Reliability based inspection policies for Auxiliary Power Unit (APU) turbine disc, probabilistic structural engineering analysis for reliability prediction of the SSME alternate turbo-pump development, impact of ET foam reliability on the Space Shuttle System risk, and reliability based Space Shuttle upgrade for safety. Special attention is given in this paper to the physics based probabilistic engineering analysis applications and their critical role in evaluating the reliability of NASA development hardware including their potential use in a research and technology development environment.

Numerical study of the SSME nozzle flow fields during transient operations: A comparison of the animated results with test

NASA Technical Reports Server (NTRS)

Wang, Ten-See; Dumas, Catherine

1993-01-01

A computational fluid dynamics (CFD) model has been applied to study the transient flow phenomena of the nozzle and exhaust plume of the Space Shuttle Main Engine (SSME), fired at sea level. The CFD model is a time accurate, pressure based, reactive flow solver. A six-species hydrogen/oxygen equilibrium chemistry is used to describe the chemical-thermodynamics. An adaptive upwinding scheme is employed for the spatial discretization, and a predictor, multiple corrector method is used for the temporal solution. Both engine start-up and shut-down processes were simulated. The elapse time is approximately five seconds for both cases. The computed results were animated and compared with the test. The images for the animation were created with PLOT3D and FAST and then animated with ABEKAS. The hysteresis effects, and the issues of free-shock separation, restricted-shock separation and the end-effects were addressed.

The Evolution of Utilizing Manual Throttles to Avoid Excessively Low LH2 NPSP at the SSME Inlet

NASA Technical Reports Server (NTRS)

Henfling, Rick

2011-01-01

In the late 1970s, years before the Space Shuttle flew its maiden voyage, it was understood low liquid hydrogen (LH2) Net Positive Suction Pressure (NPSP) at the inlet to the Space Shuttle Main Engine (SSME) could have adverse effects on engine operation. A number of failures within both the External Tank (ET) and the Orbiter Main Propulsion System (MPS) could result in a low LH2 NPSP condition, which at extremely low levels can result in cavitation of SSME turbomachinery. Operational workarounds were developed to take advantage of the onboard crew s ability to manually throttle down the SSMEs (via the Pilot s Speedbrake/Throttle Controller), which alleviated the low LH2 NPSP condition. Manually throttling the SSME to a lower power level resulted in an increase in NPSP, mainly due to the reduction in frictional flow losses while at the lower throttle setting. Early in the Space Shuttle Program s history, the relevant Flight Rule for the Booster flight controllers in Mission Control did not distinguish between ET and Orbiter MPS failures and the same crew action was taken for both. However, after a review of all Booster operational techniques following the Challenger disaster in the late 1980s, it was determined manually throttling the SSME to a lower power was only effective for Orbiter MPS failures and the Flight Rule was updated to reflect this change. The Flight Rule and associated crew actions initially called for a single throttle step to minimum power level when a low threshold for NPSP was met. As engineers refined their understanding of the NPSP requirements for the SSME (through a robust testing program), the operational techniques evolved to take advantage of the additional capabilities. This paper will examine the evolution of the Flight rule and associated procedure and how increases in knowledge about the SSME and the Space Shuttle vehicle as a whole have helped shape their development. What once was a single throttle step when NPSP decreased to a certain threshold has now become three throttle steps, each occurring at a lower NPSP threshold. Additionally the procedure, which for early Space Shuttle missions required a Return-to-Launch-Site abort, now results in a nominal Main Engine Cut Off and no loss of mission objectives.

The Evolution of Utilizing Manual Throttling to Avoid Excessively Low LH2 NPSP at the SSME Inlet

NASA Technical Reports Server (NTRS)

Henfling, Rick

2010-01-01

In the late 1970s, years before the Space Shuttle flew its maiden voyage, it was understood low liquid hydrogen (LH2) Net Positive Suction Pressure (NPSP) at the inlet to the Space Shuttle Main Engine (SSME) could have adverse effects on engine operation. A number of failures within both the External Tank (ET) and the Orbiter Main Propulsion System (MPS) could result in a low LH2 NPSP condition, which at extremely low levels can result in cavitation of SSME turbomachinery. Operational workarounds were developed to take advantage of the onboard crew s ability to manually throttle down the SSMEs (via the Pilot s Speedbrake/Throttle Controller), which alleviated the low LH2 NPSP condition. Manually throttling the SSME to a lower power level resulted in an increase in NPSP, mainly due to the reduction in frictional flow losses while at the lower throttle setting. Early in the Space Shuttle Program s history, the relevant Flight Rule for the Booster flight controller in Mission Control did not distinguish between ET and Orbiter MPS failures and the same crew action was taken for both. However, after a review of all Booster operational techniques following the Challenger disaster in the late 1980s, it was determined manually throttling the SSME to a lower power was only effective for Orbiter MPS failures and the Flight Rule was updated to reflect this change. The Flight Rule and associated crew actions initially called for a single throttle step to minimum power level when a low threshold for NPSP was met. As engineers refined their understanding of the NPSP requirements for the SSME (through a robust testing program), the operational techniques evolved to take advantage of the additional capabilities. This paper will examine the evolution of the Flight rule and associated procedure and how increases in knowledge about the SSME and the Space Shuttle vehicle as a whole have helped shape their development. What once was a single throttle step when NPSP decreased to a certain low threshold has now become three throttle steps, each occurring at a lower NPSP threshold. Additionally the procedure, which for early Space Shuttle missions required a Return-to-Launch-Site abort, now results in a nominal Main Engine Cut Off and no loss of mission objectives.

Report of the SSME assessment team

NASA Technical Reports Server (NTRS)

1993-01-01

In response to a request from the House of Representatives Committee on Science, Space, and Technology in its Report No. 102-500 of April 22, 1992, the Aerospace Safety Advisory Panel (ASAP) created an ad hoc task force to conduct a thorough assessment of the Space Shuttle Main Engine (SSME). The membership was drawn mostly from organizations other than ASAP, and this report represents the views of that task force. Its task was to assess the risk that the SSME poses to the safe operation of the Space Shuttle, to identify and evaluate improvements to the engine that would reduce the risk, and to recommend a set of priorities for the implementation of these improvements. The SSME Assessment Team, as it opted to call itself, convened in mid-1992 and, subsequently, met with and gathered information from all the principal organizations involved in the SSME program. These included the Rocketdyne Division of Rockwell International, the Marshall Space Flight Center of NASA, and the Pratt & Whitney Division of United Technologies Corporation. The information in this report reflects the program status as of October 1992. From the information received, the Team formed its conclusions and recommendations. Changes in the program status have, of course, occurred since that time; however, they did not affect the Team's conclusions and recommendations.

Engine Data Interpretation System (EDIS), phase 2

NASA Technical Reports Server (NTRS)

Cost, Thomas L.; Hofmann, Martin O.

1991-01-01

A prototype of an expert system was developed which applies qualitative constraint-based reasoning to the task of post-test analysis of data resulting from a rocket engine firing. Data anomalies are detected and corresponding faults are diagnosed. Engine behavior is reconstructed using measured data and knowledge about engine behavior. Knowledge about common faults guides but does not restrict the search for the best explanation in terms of hypothesized faults. The system contains domain knowledge about the behavior of common rocket engine components and was configured for use with the Space Shuttle Main Engine (SSME). A graphical user interface allows an expert user to intimately interact with the system during diagnosis. The system was applied to data taken during actual SSME tests where data anomalies were observed.

Radiation effect on rocket engine performance

NASA Technical Reports Server (NTRS)

Chiu, Huei-Huang; Kross, K. W.; Krebsbach, A. N.

1990-01-01

Critical problem areas involving the effect of radiation on the combustion of bipropellants are addressed by formulating a universal scaling law in combination with a radiation-enhanced vaporization combustion model. Numerical algorithms are developed and data pertaining to the Variable Thrust Engine (VTE) and the Space Shuttle Main Engine (SSME) are used to conduct parametric sensitivity studies to predict the principal intercoupling effects of radiation. The analysis reveals that low-enthalpy engines, such as the VTE, are vulnerable to a substantial performance setback due to radiative loss, whereas the performance of high-enthalpy engines such as the SSME are hardly affected over a broad range of engine operation. Combustion enhancement by radiative heating of the propellant has a significant impact on propellants with high absorptivity.

KSC-95pc586

NASA Image and Video Library

1995-04-17

KENNEDY SPACE CENTER, FLA. - Space Shuttle Main Engine (SSME) No. 2036, the first of the new Block 1 engines to fly, awaits installation into position one of the orbiter Discovery in Orbiter Processing Facility 2 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, a single-coil heat exchanger and start sequence modifications. These modifications are designed to improve both engine performance and safety.

SSME Main Combustion Chamber (MCC) hot oil dewaxing

NASA Technical Reports Server (NTRS)

Akpati, Anthony U.

1995-01-01

In an attempt to comply with the changing environmental regulations, a process was developed for the replacement of perchloroethylene in the dewaxing of the Space Shuttle Main Engine (SSME) Main Combustion Chamber (MCC) and other associated hardware filled with the Rigidax (R) casting compound. Rigidax (R) is a hard blue-dyed, calcium carbonate filled thermoplastic casting compound (melting point 77 C) that is melted and poured into hardware cavities to prevent contamination during material removal processes, i.e. machining, grinding, drilling, and deburring. Additionally, it serves as a maskant for designated areas during electroforming processes. Laboratory testing was conducted to evaluate seven alternate fluids for the replacement of perchloroethylene in the dewaxing process. Based upon successful laboratory results, a mineral oil was selected for testing on actual hardware. The final process developed involves simultaneous immersion and flushing of the MCC channels using a distinct eight stage process. A nonvolatile hydrocarbon analysis of a solvent flush sample is performed to determine the hardware cleanliness for comparison to the previous perchloroethylene dewaxing process.

SSME Main Combustion Chamber (MCC) 'Hot Oil' Dewaxing

NASA Technical Reports Server (NTRS)

Akpati, Anthony U.

1994-01-01

In an attempt to comply with the changing environmental regulations, a process was developed for the replacement of perchloroethylene in the dewaxing of the Space Shuttle Main Engine (SSME) Main Combustion Chamber (MCC) and other associated hardware filled with the Rigidax(registered mark) casting compound. Rigidax(registered mark) is a hard blue-dyed, calcium carbonate filled thermoplastic casting compound (melting point 77 C) that is melted and poured into hardware cavities to prevent contamination during material removal processes, i.e. machining, grinding, drilling, and deburring. Additionally, it serves as a maskant for designated areas during electroforming processes. Laboratory testing was conducted to evaluate seven alternate fluids for the replacement of perchloroethylene in the dewaxing process. Based upon successful laboratory results, a mineral oil was selected for testing on actual hardware. The final process developed involves simultaneous immersion and flushing of the MCC channels using a distinct eight stage process. A nonvolatile hydrocarbon analysis of a solvent flush sample is performed to determine the hardware cleanliness for comparison to the previous perchloroethylene dewaxing process.

Advanced Engine Health Management Applications of the SSME Real-Time Vibration Monitoring System

NASA Technical Reports Server (NTRS)

Fiorucci, Tony R.; Lakin, David R., II; Reynolds, Tracy D.; Turner, James E. (Technical Monitor)

2000-01-01

The Real Time Vibration Monitoring System (RTVMS) is a 32-channel high speed vibration data acquisition and processing system developed at Marshall Space Flight Center (MSFC). It Delivers sample rates as high as 51,200 samples/second per channel and performs Fast Fourier Transform (FFT) processing via on-board digital signal processing (DSP) chips in a real-time format. Advanced engine health assessment is achieved by utilizing the vibration spectra to provide accurate sensor validation and enhanced engine vibration redlines. Discrete spectral signatures (such as synchronous) that are indicators of imminent failure can be assessed and utilized to mitigate catastrophic engine failures- a first in rocket engine health assessment. This paper is presented in viewgraph form.

Stennis Space Center's approach to liquid rocket engine health monitoring using exhaust plume diagnostics

NASA Technical Reports Server (NTRS)

Gardner, D. G.; Tejwani, G. D.; Bircher, F. E.; Loboda, J. A.; Van Dyke, D. B.; Chenevert, D. J.

1991-01-01

Details are presented of the approach used in a comprehensive program to utilize exhaust plume diagnostics for rocket engine health-and-condition monitoring and assessing SSME component wear and degradation. This approach incorporates both spectral and video monitoring of the exhaust plume. Video monitoring provides qualitative data for certain types of component wear while spectral monitoring allows both quantitative and qualitative information. Consideration is given to spectral identification of SSME materials and baseline plume emissions.

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 measurement and balance uncertainty estimates. The reconciler attempts to select operational parameters that minimize the difference between theoretical prediction and observation. Selected values are further constrained to fall within measurement uncertainty limits and to satisfy fundamental physical relations (mass conservation, energy conservation, pressure drop relations, etc.) within uncertainty estimates for all SSME subsystems. The parameter selection problem described above is a traditional nonlinear programming problem. The reconciler employs a mixed penalty method to determine optimum values of SSME operating parameters associated with this problem formulation.

Dynamic balance improvement program

NASA Technical Reports Server (NTRS)

Butner, M. F.

1983-01-01

The reduction of residual unbalance in the space shuttle main engine (SSME) high pressure turbopump rotors was addressed. Elastic rotor response to unbalance and balancing requirements, multiplane and in housing balancing, and balance related rotor design considerations were assessed. Recommendations are made for near term improvement of the SSME balancing and for future study and development efforts.

Genetic algorithm based input selection for a neural network function approximator with applications to SSME health monitoring

NASA Technical Reports Server (NTRS)

Peck, Charles C.; Dhawan, Atam P.; Meyer, Claudia M.

1991-01-01

A genetic algorithm is used to select the inputs to a neural network function approximator. In the application considered, modeling critical parameters of the space shuttle main engine (SSME), the functional relationship between measured parameters is unknown and complex. Furthermore, the number of possible input parameters is quite large. Many approaches have been used for input selection, but they are either subjective or do not consider the complex multivariate relationships between parameters. Due to the optimization and space searching capabilities of genetic algorithms they were employed to systematize the input selection process. The results suggest that the genetic algorithm can generate parameter lists of high quality without the explicit use of problem domain knowledge. Suggestions for improving the performance of the input selection process are also provided.

LEADER - An integrated engine behavior and design analyses based real-time fault diagnostic expert system for Space Shuttle Main Engine (SSME)

NASA Technical Reports Server (NTRS)

Gupta, U. K.; Ali, M.

1989-01-01

The LEADER expert system has been developed for automatic learning tasks encompassing real-time detection, identification, verification, and correction of anomalous propulsion system operations, using a set of sensors to monitor engine component performance to ascertain anomalies in engine dynamics and behavior. Two diagnostic approaches are embodied in LEADER's architecture: (1) learning and identifying engine behavior patterns to generate novel hypotheses about possible abnormalities, and (2) the direction of engine sensor data processing to perform resoning based on engine design and functional knowledge, as well as the principles of the relevant mechanics and physics.

STS-55 pad abort: Engine 2011 oxidizer preburner augmented spark igniter check valve leak

NASA Technical Reports Server (NTRS)

1993-01-01

The STS-55 initial launch attempt of Columbia (OV102) was terminated on KSC launch pad A March 22, 1993 at 9:51 AM E.S.T. due to violation of an ME-3 (Engine 2011) Launch Commit Criteria (LCC) limit exceedance. The event description and timeline are summarized. Propellant loading was initiated on 22 March, 1993 at 1:15 AM EST. All SSME chill parameters and launch commit criteria (LCC) were nominal. At engine start plus 1.44 seconds, a Failure Identification (FID) was posted against Engine 2011 for exceeding the 50 psia Oxidizer Preburner (OPB) purge pressure redline. The engine was shut down at 1.50 seconds followed by Engines 2034 and 2030. All shut down sequences were nominal and the mission was safely aborted. The OPB purge pressure redline violation and the abort profile/overlay for all three engines are depicted. SSME Avionics hardware and software performed nominally during the incident. A review of vehicle data table (VDT) data and controller software logic revealed no failure indications other than the single FID 013-414, OPB purge pressure redline exceeded. Software logic was executed according to requirements and there was no anomalous controller software operation. Immediately following the abort, a Rocketdyne/NASA failure investigation team was assembled. The team successfully isolated the failure cause to the oxidizer preburner augmented spark igniter purge check valve not being fully closed due to contamination. The source of the contaminant was traced to a cut segment from a rubber O-ring which was used in a fine clean tool during valve production prior to 1992. The valve was apparently contaminated during its fabrication in 1985. The valve had performed acceptably on four previous flights of the engine, and SSME flight history shows 780 combined check valve flights without failure. The failure of an Engine 3 (SSME No. 2011) check valve to close was sensed by onboard engine instruments even though all other engine operations were normal. This resulted in an engine shutdown and safe sequential shutdown of all three engines prior to ignition of the solid boosters.

SSME model, engine dynamic characteristics related to Pogo

NASA Technical Reports Server (NTRS)

1973-01-01

A linear model of the space shuttle main engine for use in Pogo studies was presented. A digital program is included from which engine transfer functions are determined relative to the engine operating level.

An evaluation of dry film lubricants and substrate materials for use on SSME gimbal bearings

NASA Technical Reports Server (NTRS)

Harp, J. A.

1976-01-01

Failure of the spherical bearing shaft of the Space Shuttle Main Engine (SSME) gimbal bearing assembly was encountered during Design Verification Specification testing of the full scale engine. Investigation revealed that the failure was caused by a deficiency in the lubrication system. Based upon the materials and gimbal operating conditions, a lubricant of MoS2 and graphite with a ceramic binder was the best lubricant candidate for this particular application; however, the decision to implement the change was not made without verification testing. Scaled down simulation testing was performed. Four different substrate materials and eight different dry film lubricants were subjected to tests under simulated SSME environmental and stress load conditions. The test specimens were evaluated for friction and operating life. Each test specimen was subjected to cyclic operation under load until failure. The force required to move the bearing surfaces relative to each other was monitored throughout the test, thus providing analytical data for derivation of the coefficient of friction. Results indicate that the MoS2/graphite lubricant with ceramic binder proved to be superior from the standpoint of endurance and also from the standpoint of friction reducing capabilities when applied to the titanium substrate material used on SSME. Endurance of this lubricant was approximately 16 times that of the lubricant which was being used when the SSME gimbal failed.

Controls, health assessment, and conditional monitoring for large, reusable, liquid rocket engines

NASA Technical Reports Server (NTRS)

Cikanek, H. A., III

1986-01-01

Past and future progress in the performance of control systems for large, liquid rocket engines typified such as current state-of-the-art, the Shuttle Main Engine (SSME), is discussed. Details of the first decade of efforts, which culminates in the F-1 and J-2 Saturn engines control systems, are traced, noting problem modes and improvements which were implemented to realize the SSME. Future control system designs, to accommodate the requirements of operation of engines for a heavy lift launch vehicle, an orbital transfer vehicle and the aerospace plane, are summarized. Generic design upgrades needed include an expanded range of fault detection, maintenance as-needed instead of as-scheduled, reduced human involvement in engine operations, and increased control of internal engine states. Current NASA technology development programs aimed at meeting the future control system requirements are described.

SSME/side loads analysis for flight configuration, revision A. [structural analysis of space shuttle main engine under side load excitation

NASA Technical Reports Server (NTRS)

Holland, W.

1974-01-01

This document describes the dynamic loads analysis accomplished for the Space Shuttle Main Engine (SSME) considering the side load excitation associated with transient flow separation on the engine bell during ground ignition. The results contained herein pertain only to the flight configuration. A Monte Carlo procedure was employed to select the input variables describing the side load excitation and the loads were statistically combined. This revision includes an active thrust vector control system representation and updated orbiter thrust structure stiffness characteristics. No future revisions are planned but may be necessary as system definition and input parameters change.

Flowfield visualization for SSME hot gas manifold

NASA Technical Reports Server (NTRS)

Roger, Robert P.

1988-01-01

The objective of this research, as defined by NASA-Marshall Space Flight Center, was two-fold: (1) to numerically simulate viscous subsonic flow in a proposed elliptical two-duct version of the fuel side Hot Gas Manifold (HGM) for the Space Shuttle Main Engine (SSME), and (2) to provide analytical support for SSME related numerical computational experiments, being performed by the Computational Fluid Dynamics staff in the Aerophysics Division of the Structures and Dynamics Laboratory at NASA-MSFC. Numerical results of HGM were calculations to complement both water flow visualization experiments and air flow visualization experiments and air experiments in two-duct geometries performed at NASA-MSFC and Rocketdyne. In addition, code modification and improvement efforts were to strengthen the CFD capabilities of NASA-MSFC for producing reliable predictions of flow environments within the SSME.

Overview of Aerothermodynamic Loads Definition Study

NASA Technical Reports Server (NTRS)

Povinelli, L. A.

1985-01-01

The Aerothermodynamic Loads Definition were studied to develop methods to more accurately predict the operating environment in the space shuttle main engine (SSME) components. Development of steady and time-dependent, three-dimensional viscous computer codes and experimental verification and engine diagnostic testing are considered. The steady, nonsteady, and transient operating loads are defined to accurately predict powerhead life. Improvements in the structural durability of the SSME turbine drive systems depends on the knowledge of the aerothermodynamic behavior of the flow through the preburner, turbine, turnaround duct, gas manifold, and injector post regions.

SSME Investment in Turbomachinery Inducer Impeller Design Tools and Methodology

NASA Technical Reports Server (NTRS)

Zoladz, Thomas; Mitchell, William; Lunde, Kevin

2010-01-01

Within the rocket engine industry, SSME turbomachines are the de facto standards of success with regard to meeting aggressive performance requirements under challenging operational environments. Over the Shuttle era, SSME has invested heavily in our national inducer impeller design infrastructure. While both low and high pressure turbopump failures/anomaly resolution efforts spurred some of these investments, the SSME program was a major benefactor of key areas of turbomachinery inducer-impeller research outside of flight manifest pressures. Over the past several decades, key turbopump internal environments have been interrogated via highly instrumented hot-fire and cold-flow testing. Likewise, SSME has sponsored the advancement of time accurate and cavitating inducer impeller computation fluid dynamics (CFD) tools. These investments together have led to a better understanding of the complex internal flow fields within aggressive high performing inducers and impellers. New design tools and methodologies have evolved which intend to provide confident blade designs which strike an appropriate balance between performance and self induced load management.

Artificial intelligence techniques for ground test monitoring of rocket engines

NASA Technical Reports Server (NTRS)

Ali, Moonis; Gupta, U. K.

1990-01-01

An expert system is being developed which can detect anomalies in Space Shuttle Main Engine (SSME) sensor data significantly earlier than the redline algorithm currently in use. The training of such an expert system focuses on two approaches which are based on low frequency and high frequency analyses of sensor data. Both approaches are being tested on data from SSME tests and their results compared with the findings of NASA and Rocketdyne experts. Prototype implementations have detected the presence of anomalies earlier than the redline algorithms that are in use currently. It therefore appears that these approaches have the potential of detecting anomalies early eneough to shut down the engine or take other corrective action before severe damage to the engine occurs.

Engine throat/nozzle optics for plume spectroscopy

NASA Technical Reports Server (NTRS)

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

1991-01-01

The Task 2.0 Engine Throat/Nozzle Optics for Plume Spectroscopy, effort was performed under the NASA LeRC Development of Life Prediction Capabilities for Liquid Propellant Rocket Engines program. This Task produced the engineering design of an optical probe to enable spectroscopic measurements within the SSME main chamber. The probe mounts on the SSME nozzle aft manifold and collects light emitted from the throat plane and chamber. Light collected by the probe is transferred to a spectrometer through a fiber optic cable. The design analyses indicate that the probe will function throughout the engine operating cycle and is suitable for both test stand and flight operations. By detecting metallic emissions that are indicative of component degradation or incipient failure, engine shutdown can be initiated before catastrophic failure. This capability will protect valuable test stand hardware and provide enhanced mission safety.

General view of the aft fuselage of the Orbiter Discovery ...

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

General view of the aft fuselage of the Orbiter Discovery looking forward showing Space Shuttle Main Engines (SSMEs) installed in positions one and three and an SSME on the process of being installed in position two. 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

Technology test bed review

NASA Technical Reports Server (NTRS)

Mcconnaughey, H. V.

1992-01-01

The topics are presented in viewgraph form and include the following: (1) Space Shuttle Main Engine (SSME) technology test bed (TTB) history; (2) TTB objectives; (3) TTB major accomplishments; (4) TTB contributions to SSME; (5) major impacts of 3001 testing; (6) some challenges to computational fluid dynamics (CFD); (7) the high pressure fuel turbopump (HPFTP); and (8) 3001 lessons learned in design and operations.

Impact of uncertainty on modeling and testing

NASA Technical Reports Server (NTRS)

Coleman, Hugh W.; Brown, Kendall K.

1995-01-01

A thorough understanding of the uncertainties associated with the modeling and testing of the Space Shuttle Main Engine (SSME) Engine will greatly aid decisions concerning hardware performance and future development efforts. This report will describe the determination of the uncertainties in the modeling and testing of the Space Shuttle Main Engine test program at the Technology Test Bed facility at Marshall Space Flight Center. Section 2 will present a summary of the uncertainty analysis methodology used and discuss the specific applications to the TTB SSME test program. Section 3 will discuss the application of the uncertainty analysis to the test program and the results obtained. Section 4 presents the results of the analysis of the SSME modeling effort from an uncertainty analysis point of view. The appendices at the end of the report contain a significant amount of information relative to the analysis, including discussions of venturi flowmeter data reduction and uncertainty propagation, bias uncertainty documentations, technical papers published, the computer code generated to determine the venturi uncertainties, and the venturi data and results used in the analysis.

Fiber reinforced superalloys for rocket engines

NASA Technical Reports Server (NTRS)

Petrasek, Donald W.; Stephens, Joseph R.

1989-01-01

High pressure turbopumps for advanced reusable liquid propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several fold increase in life and over a 200 C increase in temperature capability over the current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Fiber reinforced superalloys for rocket engines

NASA Technical Reports Server (NTRS)

Petrasek, Donald W.; Stephens, Joseph R.

1988-01-01

High-pressure turbopumps for advanced reusable liquid-propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several-fold increase in life and over a 200C increase in temperature capability over current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

A function approximation approach to anomaly detection in propulsion system test data

NASA Technical Reports Server (NTRS)

Whitehead, Bruce A.; Hoyt, W. A.

1993-01-01

Ground test data from propulsion systems such as the Space Shuttle Main Engine (SSME) can be automatically screened for anomalies by a neural network. The neural network screens data after being trained with nominal data only. Given the values of 14 measurements reflecting external influences on the SSME at a given time, the neural network predicts the expected nominal value of a desired engine parameter at that time. We compared the ability of three different function-approximation techniques to perform this nominal value prediction: a novel neural network architecture based on Gaussian bar basis functions, a conventional back propagation neural network, and linear regression. These three techniques were tested with real data from six SSME ground tests containing two anomalies. The basis function network trained more rapidly than back propagation. It yielded nominal predictions with, a tight enough confidence interval to distinguish anomalous deviations from the nominal fluctuations in an engine parameter. Since the function-approximation approach requires nominal training data only, it is capable of detecting unknown classes of anomalies for which training data is not available.

CFD simulation of coaxial injectors

NASA Technical Reports Server (NTRS)

Landrum, D. Brian

1993-01-01

The development of improved performance models for the Space Shuttle Main Engine (SSME) is an important, ongoing program at NASA MSFC. These models allow prediction of overall system performance, as well as analysis of run-time anomalies which might adversely affect engine performance or safety. Due to the complexity of the flow fields associated with the SSME, NASA has increasingly turned to Computational Fluid Dynamics (CFD) techniques as modeling tools. An important component of the SSME system is the fuel preburner, which consists of a cylindrical chamber with a plate containing 264 coaxial injector elements at one end. A fuel rich mixture of gaseous hydrogen and liquid oxygen is injected and combusted in the chamber. This process preheats the hydrogen fuel before it enters the main combustion chamber, powers the hydrogen turbo-pump, and provides a heat dump for nozzle cooling. Issues of interest include the temperature and pressure fields at the turbine inlet and the thermal compatibility between the preburner chamber and injector plate. Performance anomalies can occur due to incomplete combustion, blocked injector ports, etc. The performance model should include the capability to simulate the effects of these anomalies. The current approach to the numerical simulation of the SSME fuel preburner flow field is to use a global model based on the MSFC sponsored FNDS code. This code does not have the capabilities of modeling several aspects of the problem such as detailed modeling of the coaxial injectors. Therefore, an effort has been initiated to develop a detailed simulation of the preburner coaxial injectors and provide gas phase boundary conditions just downstream of the injector face as input to the FDNS code. This simulation should include three-dimensional geometric effects such as proximity of injectors to baffles and chamber walls and interaction between injectors. This report describes an investigation into the numerical simulation of GH2/LOX coaxial injectors. The following sections will discuss the physical aspects of injectors, the CFD code employed, and preliminary results of a simulation of a single coaxial injector for which experimental data is available. It is hoped that this work will lay the foundation for the development of a unique and useful tool to support the SSME program.

SSME structural computer program development. Volume 3: BOPACE demonstration analysis of the SSME thrust chamber liner

NASA Technical Reports Server (NTRS)

Spring, A. H.

1973-01-01

The application of a structural computer program for analysis of a thrust chamber liner is discussed. Two objectives were accomplished as follows: (1) exercise of the full capabilities of the computer program and (2) definition of thermal and mechanical boundary conditions to reflect the emergency power level operating conditions for the SSME 47OK engine at a station just upstream of the thrust chamber throat. Creep information on the thrust chamber is presented as a reference curve of creep strain versus time for various temperatures. Contour plots of the effective plastic strain, effective stress, and effective creep strain are developed.

SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture

NASA Technical Reports Server (NTRS)

Ballard, Richard O.

2015-01-01

A key constituent of the NASA Space Launch System (SLS) architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). This engine was selected largely due to the maturity and extensive experience gained through 30-plus years of service. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle and mounting it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration and operational details, there were also hardware upgrades needed. While the magnitude of effort is less than that needed to develop a new clean-sheet engine system, this paper describes some of the expected and unexpected challenges encountered to date on the path to the first flight of SLS.

Development of Life Prediction Capabilities for Liquid Propellant Rocket Engines. Task 4. Post-Fire Diagnostic System for the SSME System Architecture Study.

DTIC Science & Technology

1991-07-31

90 START MCC LN CAV PR 3 UNDERSHOOT ABOVE THRESHOLD YES MI A2-492 2/13/90 MAINSTAGE HPOT DS TMP CHANNEL A/B DIVERGENCE NO MI A2-492 2/13/90 MAINSTAGE ...System for the SSME System Architecture Study Y, , Contract NAS 3 -25883 JUL 31󈧣 CR-187112 Prepared for: National Aeronautics and Space...Liquid Propellant Rocket Engines Contract No. NAS 3 -25883 Eli Ki ,,, July 31, 1991 BY Dist Prepared By.: Mr. Mark Gage Aerojet Propulsion Division Box

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.

Calculations of combustion response profiles and oscillations

NASA Technical Reports Server (NTRS)

Priem, Richard J.; Breisacher, Kevin J.

1993-01-01

The theory and procedures for determining the characteristics of pressure oscillations in rocket engines with prescribed burning rate oscillations are presented. Pressure and velocity oscillations calculated using this procedure are presented for the Space Shuttle Main Engine (SSME) to show the influence of baffles and absorbers on the burning rate oscillations required to achieve neutral stability. Results of calculations to determine local combustion responses using detailed physical models for injection, atomization, and vaporization with gas phase oscillations in baffled and unbaffled SSME combustors are presented. The contributions of the various physical phenomena occurring in a combustor to oscillations in combustion response were determined.

Probabilistic Structural Analysis Methods for select space propulsion system components (PSAM). Volume 2: Literature surveys of critical Space Shuttle main engine components

NASA Technical Reports Server (NTRS)

Rajagopal, K. R.

1992-01-01

The technical effort and computer code development is summarized. Several formulations for Probabilistic Finite Element Analysis (PFEA) are described with emphasis on the selected formulation. The strategies being implemented in the first-version computer code to perform linear, elastic PFEA is described. The results of a series of select Space Shuttle Main Engine (SSME) component surveys are presented. These results identify the critical components and provide the information necessary for probabilistic structural analysis. Volume 2 is a summary of critical SSME components.

Real-time failure control (SAFD)

NASA Technical Reports Server (NTRS)

Panossian, Hagop V.; Kemp, Victoria R.; Eckerling, Sherry J.

1990-01-01

The Real Time Failure Control program involves development of a failure detection algorithm, referred as System for Failure and Anomaly Detection (SAFD), for the Space Shuttle Main Engine (SSME). This failure detection approach is signal-based and it entails monitoring SSME measurement signals based on predetermined and computed mean values and standard deviations. Twenty four engine measurements are included in the algorithm and provisions are made to add more parameters if needed. Six major sections of research are presented: (1) SAFD algorithm development; (2) SAFD simulations; (3) Digital Transient Model failure simulation; (4) closed-loop simulation; (5) SAFD current limitations; and (6) enhancements planned for.

Summary of Recent Inducer Testing at MSFC and Future Plans

NASA Technical Reports Server (NTRS)

Skelley, Stephen

2003-01-01

This viewgraph presentation covers water flow tests on the RS-83 Main LOX Inducer for the Space Shuttle Main Engine (SSME). The presentation lists recent water tests on the SSME liquid oxygen (LOX) pump inducer, includes images and diagrams of the water test facility at Marshall Space Flight Center (MSFC), profiles inducer hydrodynamic forces, and diagrams the performance of the RS-83 inducer.

Rocket Noise and Vibration Shuttle/Payload Processing and ISS: Launch Pad Vibroacoustics Research at NASA/KSC

NASA Technical Reports Server (NTRS)

Margasayam, Ravi; Voska, Ned (Technical Monitor)

2002-01-01

This viewgraph presentation provides information on the effects of noise of the SSME Space Shuttle Main Engine upon liftoff from Kennedy Space Center. It covers both effects experienced by astronauts within the Shuttles, and effects on the surrounding environment. The presentation then makes recommendations for design methods which take into account vibroacoustics.

Space Shuttle Project

NASA Image and Video Library

1996-12-16

A NASA scientist displays Space Shuttle Main Engine (SSME) turbine component which underwent air flow tests at Marshall's Structures and Dynamics Lab. Such studies could improve efficiency of aircraft engines, and lower operational costs.

Modeling of SSME fuel preburner ASI

NASA Technical Reports Server (NTRS)

Liang, Pak-Yan

1992-01-01

The Augmented Spark Ignitor (ASI) is a LOX/H2/electrical spark system that functions as an ignition source and sustainer for stable combustion. It is used in the Space Shuttle Main Engine (SSME) preburner combustor, the SMME main combustion chamber, the J-1 and J-2 engines, as well as proposed designs of the Space Transportation Main Engine (STME) main combustor and gas generators. An undertaking to characterize the flow of the ASI is documented. The code consists of a marriage of the Implicit-Continuous Eulerian/Arbitrary Lagrangian Code (ICE-ALE) Navier-Stokes solver with the Volume-of-Fluid (VOF) Methodology for tracking of two immiscible fluids with sharp discontinuities. Spray droplets are represented by discrete numerical parcels tracked in a Lagrangian fashion. Numerous physical sub-models are also incorporated to describe the processes of atomization, droplet collision, droplet breakup, evaporation, and droplet and gas phase turbulence. An equilibrium chemistry model accounting for 8 active gaseous species is also used. Taking advantage of this symmetry plane, half of the actual ASI is modeled with a 3-D grid that geometrically resolves the LOX ports, the spark plug locations, and the hydrogen injection slots.

KSC-2012-1025

NASA Image and Video Library

2012-01-12

CAPE CANAVERAL, Fla. – In the Space Shuttle Main Engine Processing Facility at NASA’s Kennedy Space Center in Florida, a technician oversees the closure of a transportation canister containing a Pratt Whitney Rocketdyne space shuttle main engine (SSME). This is the second of the 15 engines used during the Space Shuttle Program to be prepared for transfer to NASA's Stennis Space Center in Mississippi. The engines will be stored at Stennis for future use on NASA's new heavy-lift rocket, the Space Launch System (SLS), which will carry NASA's new Orion spacecraft, cargo, equipment and science experiments to space. For more information, visit http://www.nasa.gov/shuttle. Photo credit: NASA/Gianni Woods

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.

Systems Modeling of a Hypothetical SSME Channel-Wall Nozzle

NASA Technical Reports Server (NTRS)

Greene, William D.; Thames, Mignon P.; Polsgrove, Robert H.

2003-01-01

A future upgrade to the Space Shuttle Main Engine (SSME) may be the replacement of the current regenerative cooled tube-wall nozzle with a nozzle using a regeneratively-cooled channel-wall design. The current tube-wall design represents the only major piece of SSME hardware that has not been dramatically updated throughout thc long history of the engine. There are a number of advantages to a channel-wall design including the promise of faster and lower cost fabrication and greater reliability in the field. The technical obstacles in the path of making this happen are many, particularly in the realms of metallurgy and manufacturing techniques. However, one technical area that can and should be addressed in the near term as part of the development of detailed component requirements is a systems type model of the fluid flow and heat transfer processes to which the new design will be exposed. This paper presents the results of an effort to develop a mathematical model of the internal flow for a generic channel-wall nozzle functioning as a direct replacement for the current tube-wall nozzle with a minimum of systems-level changes. Comparisons will be made to mathematical modeling results for the current tube-wall design and the results of various geometrical trade studies will be presented. It is the intent of this work to examine the feasibility of the concept of a direct replacement component with minimum systems-!eve impacts and to highlight potential areas of concern requiring further work in the future.

Application of single crystal superalloys for Earth-to-orbit propulsion systems

NASA Technical Reports Server (NTRS)

Dreshfield, R. L.; Parr, R. A.

1987-01-01

Single crystal superalloys were first identified as potentially useful engineering materials for aircraft gas turbine engines in the mid-1960's. Although they were not introduced into service as turbine blades in commercial aircraft engines until the early 1980's, they have subsequently accumulated tens of millions of flight hours in revenue producing service. The space shuttle main engine (SSME) and potential advanced earth-to-orbit propulsion systems impose severe conditions on turbopump turbine blades which for some potential failure modes are more severe than in aircraft gas turbines. Research activities which are directed at evaluating the potential for single crystal superalloys for application as turbopump turbine blades in the SSME and advanced rocket engines are discussed. The mechanical properties of these alloys are summarized and the effects of hydrogen are noted. The use of high gradient directional solidification and hot isostatic pressing to improve fatigue properties is also addressed.

A Change of Inertia-Supporting the Thrust Vector Control of the Space Launch System

NASA Technical Reports Server (NTRS)

Dziubanek, Adam J.

2012-01-01

The Space Launch System (SLS) is America's next launch vehicle. To utilize the vehicle more economically, heritage hardware from the Space Transportation System (STS) will be used when possible. The Solid Rocket Booster (SRB) actuators could possibly be used in the core stage of the SLS. The dynamic characteristics of the SRB actuator will need to be tested on an Inertia Load Stand (ILS) that has been converted to Space Shuttle Main Engine (SSME). The inertia on the pendulum of the ILS will need to be changed to match the SSME inertia. In this testing environment an SRB actuator can be tested with the equivalent resistence of an SSME.

Reusable rocket engine turbopump condition monitoring

NASA Technical Reports Server (NTRS)

Hampson, M. E.; Barkhoudarian, S.

1985-01-01

Significant improvements in engine readiness with attendant reductions in maintenance costs and turnaround times can be achieved with an engine condition monitoring system (CMS). The CMS provides real time health status of critical engine components, without disassembly, through component monitoring with advanced sensor technologies. Three technologies were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiber optic deflectometer (bearings), and the fiber optic pyrometer (blades). Signal processing algorithms were evaluated and ranked for their utility in providing useful component health data to unskilled maintenance personnel. Design modifications to current configuration Space Shuttle Main Engine (SSME) high pressure turbopumps and the MK48-F turbopump were developed to incorporate the sensors.

Probabilistic structural analysis methods for improving Space Shuttle engine reliability

NASA Technical Reports Server (NTRS)

Boyce, L.

1989-01-01

Probabilistic structural analysis methods are particularly useful in the design and analysis of critical structural components and systems that operate in very severe and uncertain environments. These methods have recently found application in space propulsion systems to improve the structural reliability of Space Shuttle Main Engine (SSME) components. A computer program, NESSUS, based on a deterministic finite-element program and a method of probabilistic analysis (fast probability integration) provides probabilistic structural analysis for selected SSME components. While computationally efficient, it considers both correlated and nonnormal random variables as well as an implicit functional relationship between independent and dependent variables. The program is used to determine the response of a nickel-based superalloy SSME turbopump blade. Results include blade tip displacement statistics due to the variability in blade thickness, modulus of elasticity, Poisson's ratio or density. Modulus of elasticity significantly contributed to blade tip variability while Poisson's ratio did not. Thus, a rational method for choosing parameters to be modeled as random is provided.

Cryogenic, high speed, turbopump bearing cooling requirements

NASA Technical Reports Server (NTRS)

Dolan, Fred J.; Gibson, Howard G.; Cannon, James L.; Cody, Joe C.

1988-01-01

Although the Space Shuttle Main Engine (SSME) has repeatedly demonstrated the capability to perform during launch, the High Pressure Oxidizer Turbopump (HPOTP) main shaft bearings have not met their 7.5 hour life requirement. A tester is being employed to provide the capability of subjecting full scale bearings and seals to speeds, loads, propellants, temperatures, and pressures which simulate engine operating conditions. The tester design permits much more elaborate instrumentation and diagnostics than could be accommodated in an SSME turbopump. Tests were made to demonstrate the facilities; and the devices' capabilities, to verify the instruments in its operating environment and to establish a performance baseline for the flight type SSME HPOTP Turbine Bearing design. Bearing performance data from tests are being utilized to generate: (1) a high speed, cryogenic turbopump bearing computer mechanical model, and (2) a much improved, very detailed thermal model to better understand bearing internal operating conditions. Parametric tests were also made to determine the effects of speed, axial loads, coolant flow rate, and surface finish degradation on bearing performance.

Total Quality Management in Space Shuttle Main Engine manufacturing

NASA Technical Reports Server (NTRS)

Ding, J.

1992-01-01

The Total Quality Management (TQM) philosophy developed in the Marshall Space Flight Center (MSFC) is briefly reviewed and the ongoing TQM implementation effort which is being pursued through the continuous improvement (CI) process is discussed. TQM is based on organizational excellence which integrates the new supportive culture with the technical tools necessary to identify, assess, and correct manufacturing processes. Particular attention is given to the prime contractor's change to the organizational excellence management philosophy in SSME manufacturing facilities.

Reduced Order Modeling of SLS Liquid Hydrogen Pre-Valve Flow Guide to Enable Rapid Transient Analysis

NASA Technical Reports Server (NTRS)

Brown, Andrew M.; Mulder, Andrew

2017-01-01

NASA is developing a new launch vehicle, called the Space Launch System (SLS), which is intended on taking humans out of low earth orbit to destinations including the moon, asteroids, and Mars. The propulsion system for the core stage of this vehicle includes four RS-25 Liquid Hydrogen/Oxygen rocket engines. These engines are upgraded versions of the Space Shuttle Main Engines (SSME); the upgrades include higher power levels and affordability enhancements. As with any new vehicle, the Main Propulsion System (MPS), which include the feedlines and ancillary hardware connecting the engines to the fuel and oxidizer tanks, had to be redesigned (figure 1 - export clearance in progress), as the previous MPS for the SSME's was inherently part of the Space Shuttle System, which had a completely different overall configuration.

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.

Neural network architectures to analyze OPAD data

NASA Technical Reports Server (NTRS)

Whitaker, Kevin W.

1992-01-01

A prototype Optical Plume Anomaly Detection (OPAD) system is now installed on the space shuttle main engine (SSME) Technology Test Bed (TTB) at MSFC. The OPAD system requirements dictate the need for fast, efficient data processing techniques. To address this need of the OPAD system, a study was conducted into how artificial neural networks could be used to assist in the analysis of plume spectral data.

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.

Identification and detection of anomalies through SSME data analysis

NASA Technical Reports Server (NTRS)

Pereira, Lisa; Ali, Moonis

1990-01-01

The goal of the ongoing research described in this paper is to analyze real-time ground test data in order to identify patterns associated with the anomalous engine behavior, and on the basis of this analysis to develop an expert system which detects anomalous engine behavior in the early stages of fault development. A prototype of the expert system has been developed and tested on the high frequency data of two SSME tests, namely Test #901-0516 and Test #904-044. The comparison of our results with the post-test analyses indicates that the expert system detected the presence of the anomalies in a significantly early stage of fault development.

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

The objective of the research project described is to define and demonstrate methods to advance the state of the art of pressure sensors for the space shuttle main engine (SSME). Silicon piezoresistive technology was utilized in completing tasks: generation and testing of three transducer design concepts for solid state applications; silicon resistor characterization at cryogenic temperatures; experimental chip mounting characterization; frequency response optimization and prototype design and fabrication. Excellent silicon sensor performance was demonstrated at liquid nitrogen temperature. A silicon resistor ion implant dose was customized for SSME temperature requirements. A basic acoustic modeling software program was developed as a design tool to evaluate frequency response characteristics.

Main propulsion system test requirements for the two-engine Shuttle-C

NASA Technical Reports Server (NTRS)

Lynn, E. E.; Platt, G. K.

1989-01-01

The Shuttle-C is an unmanned cargo carrying derivative of the space shuttle with optional two or three space shuttle main engines (SSME's), whereas the shuttle has three SSME's. Design and operational differences between the Shuttle-C and shuttle were assessed to determine requirements for additional main propulsion system (MPS) verification testing. Also, reviews were made of the shuttle main propulsion test program objectives and test results and shuttle flight experience. It was concluded that, if significant MPS modifications are not made beyond those currently planned, then main propulsion system verification can be concluded with an on-pad flight readiness firing.

Real-time diagnostics of the reusable rocket engine using on-line system identification

NASA Technical Reports Server (NTRS)

Guo, T.-H.; Merrill, W.; Duyar, A.

1990-01-01

A model-based failure diagnosis system has been proposed for real-time diagnosis of SSME failures. Actuation, sensor, and system degradation failure modes are all considered by the proposed system. In the case of SSME actuation failures, it was shown that real-time identification can effectively be used for failure diagnosis purposes. It is a direct approach since it reduces the detection, isolation, and the estimation of the extent of the failures to the comparison of parameter values before and after the failure. As with any model-based failure detection system, the proposed approach requires a fault model that embodies the essential characteristics of the failure process. The proposed diagnosis approach has the added advantage that it can be used as part of an intelligent control system for failure accommodation purposes.

STS-47 Pilot Brown on OV-105's flight deck ten minutes after SSME cutoff

NASA Technical Reports Server (NTRS)

1992-01-01

STS-47 Pilot Curtis L. Brown, Jr, is photographed at Endeavour's, Orbiter Vehicle (OV) 105's, pilot station about ten minutes after space shuttle main engine (SSME) cutoff on launch day. Brown smiles from inside the launch and entry suit (LES) and launch and entry helmet (LEH). In the background are the flight mirror assembly silhouetted against forward window W5, control panels, and a checklist.

STS-26 Discovery, OV-103, SSME (2019) installed in position number one at KSC

NASA Image and Video Library

1988-01-10

S88-29076 (10 Jan 1988) --- KSC employees work together to carefully guide a 7,000 pound main engine into the number one position in Discovery's aft compartment. Because of the engine's weight and size, special handling equipment is needed to perform the installation. Discovery is currently being prepared for the upcoming STS-26 mission in bay 1 of the Orbiter Processing Facility. This engine, 2019, arrived at KSC on Jan. 6 and was installed Jan. 10. The other two engines are scheduled to be installed later this month. The shuttle's three main liquid fueled engines provide the main propulsion for the orbiter vehicle. The cluster of three engines operate in parallel with the solid rocket boosters during the initial ascent.

Close-up of SSME

NASA Technical Reports Server (NTRS)

1994-01-01

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.

OPAD status report - Investigation of SSME component erosion

NASA Astrophysics Data System (ADS)

Powers, W. T.; Cooper, A. E.; Wallace, T. L.

1992-04-01

Significant erosion of preburner faceplates was observed during recent SSME test firings at the NASA Technology Test Bed (TTB). The OPAD instrumentation acquired exhaust-plume spectral data during each test which indicate the occurrence of metallic species consistent with faceplate component composition. A qualitative analysis of the spectral data was conducted to evaluate the state of the engine versus time for each test according to the nominal conditions of TTB firing number 17 and number 18. In general the analyses indicate abnormal erosion levels at or near startup. Subsequent to the initial erosion event, signal levels tend to decrease towards nominal baseline values. These findings, in conjunction with post-test engine inspections, suggest that in cases under study, the erosion may not have been catastrophic to the immediate operation of the engine.

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.

Experimental Flow Models for SSME Flowfield Characterization

NASA Technical Reports Server (NTRS)

Abel, L. C.; Ramsey, P. E.

1989-01-01

Full scale flow models with extensive instrumentation were designed and manufactured to provide data necessary for flow field characterization in rocket engines of the Space Shuttle Main Engine (SSME) type. These models include accurate flow path geometries from the pre-burner outlet through the throat of the main combustion chamber. The turbines are simulated with static models designed to provide the correct pressure drop and swirl for specific power levels. The correct turbopump-hot gas manifold interfaces were designed into the flow models to permit parametric/integration studies for new turbine designs. These experimental flow models provide a vehicle for understanding the fluid dynamics associated with specific engine issues and also fill the more general need for establishing a more detailed fluid dynamic base to support development and verification of advanced math models.

Preliminary vibration, acoustic, and shock design and test criteria for components on the SRB, ET, and SSME

NASA Technical Reports Server (NTRS)

1976-01-01

Specifications for vibration, acoustic and shock design for components and subassemblies on the External Tank (ET), Solid Rocket Booster (SRB), and Space Shuttle Main Engine (SSME). Included are vibration, acoustic, shock, transportation, handling, and acceptance test requirements and procedures. The space shuttle ET, SRB, and SSME have been divided into zones and subzones. Zones are designated primarily to assist in determining the applicable specifications. A subzone (General Specification) is available for use when the location of the component is known but component design and weight are not well defined. When the location, weight, and mounting configuration of the component are known, specifications for appropriate subzone weight ranges are available. Criteria for some specific components are also presented.

Development of an intelligent diagnostic system for reusable rocket engine control

NASA Technical Reports Server (NTRS)

Anex, R. P.; Russell, J. R.; Guo, T.-H.

1991-01-01

A description of an intelligent diagnostic system for the Space Shuttle Main Engines (SSME) is presented. This system is suitable for incorporation in an intelligent controller which implements accommodating closed-loop control to extend engine life and maximize available performance. The diagnostic system architecture is a modular, hierarchical, blackboard system which is particularly well suited for real-time implementation of a system which must be repeatedly updated and extended. The diagnostic problem is formulated as a hierarchical classification problem in which the failure hypotheses are represented in terms of predefined data patterns. The diagnostic expert system incorporates techniques for priority-based diagnostics, the combination of analytical and heuristic knowledge for diagnosis, integration of different AI systems, and the implementation of hierarchical distributed systems. A prototype reusable rocket engine diagnostic system (ReREDS) has been implemented. The prototype user interface and diagnostic performance using SSME test data are described.

Flow Distribution Around the SSME Main Injector Assembly Using Porosity Formulation

NASA Technical Reports Server (NTRS)

Cheng, Gary C.; Chen, Yen-Sen; Wang, Ten-See

1995-01-01

Hot gas turbulent flow distribution around the main injector assembly of the Space Shuttle Main Engine (SSME) and Liquid Oxidizer (LOX) flow distribution through the LOX posts have a great effect on the combustion phenomena inside the main combustion chamber. In order to design a CFD model to be an effective engineering analysis tool with good computational turn- around time (especially for 3-D flow problems) and still maintain good accuracy in describing the flow features, the concept of porosity was employed to describe the effects of blockage and drag force due to the presence of the LOX posts in the turbulent flow field around the main injector assembly of the SSME. 2-D numerical studies were conducted to identify the drag coefficients of the flows both through tube banks and around the shielded posts over a wide range of Reynolds numbers. Empirical, analytical expressions of the drag coefficient as a function of local flow Reynolds number were then deduced. The porosity model was applied to the turbulent flow around the main injector assembly of the SSME, and analyses were performed. The 3-D CFD analysis was divided into three parts, LOX dome, hot gas injector assembly, and hydrogen cavity. The numerical results indicate that the mixture ratio at the downstream of injector face was close to stoichiometric around baffle elements.

Flow Distribution Around the SSME Main Injector Assembly Using Porosity Formulation

NASA Technical Reports Server (NTRS)

Cheng, Gary C.; Chen, Yen-Sen; Wang, Ten-See

1995-01-01

Hot gas turbulent flow distribution around the main injector assembly of the Space Shuttle Main Engine (SSME) and Liquid Oxidizer (LOX) flow distribution through the LOX posts have a great effect on the combustion phenomena inside the main combustion chamber. In order to design a CFD model to be an effective engineering analysis tool with good computational turn-around time (especially for 3-D flow problems) and still maintain good accuracy in describing the flow features, the concept of porosity was employed to describe the effects of blockage and drag force due to the presence of the LOX posts in the turbulent flow field around the main injector assembly of the SSME. 2-D numerical studies were conducted to identify the drag coefficients of the flows both through tube banks and around the shielded posts over a wide range of Reynolds numbers. Empirical, analytical expressions of the drag coefficient as a function of local flow Reynolds number were then deduced. The porosity model was applied to the turbulent flow around the main injector assembly of the SSME, and analyses were performed. The 3-D CFD analysis was divided into three parts, LOX dome, hot gas injector assembly, and hydrogen cavity. The numerical results indicate that the mixture ratio at the downstream of injector face was close to stoichiometric around baffle elements.

Shuttle Propulsion Overview - The Design Challenges

NASA Technical Reports Server (NTRS)

Owen, James W.

2011-01-01

The major elements of the Space Shuttle Main Propulsion System include two reusable solid rocket motors integrated into recoverable solid rocket boosters, an expendable external fuel and oxidizer tank, and three reusable Space Shuttle Main Engines. Both the solid rocket motors and space shuttle main engines ignite prior to liftoff, with the solid rocket boosters separating about two minutes into flight. The external tank separates, about eight and a half minutes into the flight, after main engine shutdown and is safely expended in the ocean. The SSME's, integrated into the Space Shuttle Orbiter aft structure, are reused after post landing inspections. The configuration is called a stage and a half as all the propulsion elements are active during the boost phase, with only the SSME s continuing operation to achieve orbital velocity. Design and performance challenges were numerous, beginning with development work in the 1970's. The solid rocket motors were large, and this technology had never been used for human space flight. The SSME s were both reusable and very high performance staged combustion cycle engines, also unique to the Space Shuttle. The multi body side mount configuration was unique and posed numerous integration and interface challenges across the elements. Operation of the system was complex and time consuming. This paper describes the design challenges and key areas where the design evolved during the program.

The design of two-stage-to-orbit vehicles

NASA Technical Reports Server (NTRS)

1991-01-01

Two separate student design groups developed conceptual designs for a two-stage-to-orbit vehicle, with each design group consisting of a carrier team and an orbiter team. A two-stage-to-orbit system is considered in the event that single-stage-to-orbit is deemed not feasible in the foreseeable future; the two-stage system would also be used as a complement to an already existing heavy lift vehicle. The design specifications given are to lift a 10,000-lb payload 27 ft long by 10 ft diameter, to low Earth orbit (300 n.m.) using an air breathing carrier configuration that will take off horizontally within 15,000 ft. The staging Mach number and altitude were to be determined by the design groups. One group designed a delta wing/body carrier with the orbiter nested within the fuselage of the carrier, and the other group produced a blended cranked-delta wing/body carrier with the orbiter in the more conventional piggyback configuration. Each carrier used liquid hydrogen-fueled turbofanramjet engines, with data provided by General Electric Aircraft Engine Group. While one orbiter used a full-scale Space Shuttle Main Engine (SSME), the other orbiter employed a half-scale SSME coupled with scramjet engines, with data again provided by General Electric. The two groups conceptual designs, along with the technical trade-offs, difficulties, and details that surfaced during the design process are presented.

Rocket Engine Plume Diagnostics at Stennis Space Center

NASA Technical Reports Server (NTRS)

Tejwani, Gopal D.; Langford, Lester A.; VanDyke, David B.; McVay, Gregory P.; Thurman, Charles C.

2003-01-01

The Stennis Space Center has been at the forefront of development and application of exhaust plume spectroscopy to rocket engine health monitoring since 1989. Various spectroscopic techniques, such as emission, absorption, FTIR, LIF, and CARS, have been considered for application at the engine test stands. By far the most successful technology h a been exhaust plume emission spectroscopy. In particular, its application to the Space Shuttle Main Engine (SSME) ground test health monitoring has been invaluable in various engine testing and development activities at SSC since 1989. On several occasions, plume diagnostic methods have successfully detected a problem with one or more components of an engine long before any other sensor indicated a problem. More often, they provide corroboration for a failure mode, if any occurred during an engine test. This paper gives a brief overview of our instrumentation and computational systems for rocket engine plume diagnostics at SSC. Some examples of successful application of exhaust plume spectroscopy (emission as well as absorption) to the SSME testing are presented. Our on-going plume diagnostics technology development projects and future requirements are discussed.

Radiation effect on rocket engine performance

NASA Technical Reports Server (NTRS)

Chiu, Huei-Huang

1988-01-01

The effects of radiation on the performance of modern rocket propulsion systems operating at high pressure and temperature were recognized as a key issue in the design and operation of various liquid rocket engines of the current and future generations. Critical problem areas of radiation coupled with combustion of bipropellants are assessed and accounted for in the formulation of a universal scaling law incorporated with a radiation-enhanced vaporization combustion model. Numerical algorithms are developed and the pertaining data of the Variable Thrust Engine (VTE) and Space Shuttle Main Engine (SSME) are used to conduct parametric sensitivity studies to predict the principal intercoupling effects of radiation. The analysis reveals that low enthalpy engines, such as the VTE, are vulnerable to a substantial performance set back by the radiative loss, whereas the performance of high enthalpy engines such as the SSME, are hardly affected over a broad range of engine operation. Additionally, combustion enhancement by the radiative heating of the propellant has a significant impact in those propellants with high absorptivity. Finally, the areas of research related with radiation phenomena in bipropellant engines are identified.

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.

Modeling of rolling element bearing mechanics

NASA Technical Reports Server (NTRS)

Greenhill, L. M.

1991-01-01

Roller element bearings provide the primary mechanical interface between rotating and nonrotating components in the high performance turbomachinery of the Space Shuttle Main Engine (SSME). Knowledge of bearing behavior under various loading and environmental conditions is essential to predicting and understanding the overall behavior of turbopumps, including rotordynamic stability, critical speeds and bearing life. The objective is to develop mathematical models and computer programs to describe the mechanical behavior of ball and cylinder roller bearings under the loading and environmental conditions encountered in the SSME and future high performance rocket engines. This includes characteristics such as nonlinear load/motion relationships, stiffness and damping, rolling element loads for life prediction, and roller and cage stability.

Using a data base management system for modelling SSME test history data

NASA Technical Reports Server (NTRS)

Abernethy, K.

1985-01-01

The usefulness of a data base management system (DBMS) for modelling historical test data for the complete series of static test firings for the Space Shuttle Main Engine (SSME) was assessed. From an analysis of user data base query requirements, it became clear that a relational DMBS which included a relationally complete query language would permit a model satisfying the query requirements. Representative models and sample queries are discussed. A list of environment-particular evaluation criteria for the desired DBMS was constructed; these criteria include requirements in the areas of user-interface complexity, program independence, flexibility, modifiability, and output capability. The evaluation process included the construction of several prototype data bases for user assessement. The systems studied, representing the three major DBMS conceptual models, were: MIRADS, a hierarchical system; DMS-1100, a CODASYL-based network system; ORACLE, a relational system; and DATATRIEVE, a relational-type system.

An SSME high pressure oxidizer turbopump diagnostic system using G2(TM) real-time expert system

NASA Technical Reports Server (NTRS)

Guo, Ten-Huei

1991-01-01

An expert system which diagnoses various seal leakage faults in the High Pressure Oxidizer Turbopump of the SSME was developed using G2(TM) real-time expert system. Three major functions of the software were implemented: model-based data generation, real-time expert system reasoning, and real-time input/output communication. This system is proposed as one module of a complete diagnostic system for Space Shuttle Main Engine. Diagnosis of a fault is defined as the determination of its type, severity, and likelihood. Since fault diagnosis is often accomplished through the use of heuristic human knowledge, an expert system based approach was adopted as a paradigm to develop this diagnostic system. To implement this approach, a software shell which can be easily programmed to emulate the human decision process, the G2 Real-Time Expert System, was selected. Lessons learned from this implementation are discussed.

Investigation of the feasibility of temperature profiling optical diagnostics in the SSME fuel pre-burner

NASA Technical Reports Server (NTRS)

Shirley, J. A.

1983-01-01

Results of an analytical investigation to determine the feasibility of temperature profiling in the space shuttle main engine (SSME) fuel preburner are presented. In this application it is desirable to measure temperature in the preburner combustor with a remote, nonintrusive optical technique. Several techniques using laser excitation were examined with a consideration of the constraints imposed by optical access in the fuel preburner and the problems associated with operation near the functioning space shuttle engine. The potential performance of practical diagnostic systems based on spontaneous Raman backscattering, laser induced fluorescence, and coherent anti-Stokes Raman spectroscopy were compared analytically. A system using collection of spontaneous Raman backscattering excited by a remotely located 5 to 10 watt laser propagated to the SSME through a small diameter optical fiber was selected as the best approach. Difficulties normally associated with Raman scattering: weak signal strength and interference due to background radiation are not expected to be problematic due to the very high density in this application, and the low flame luminosity expected in the fuel rich hydrogen oxygen flame.

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.

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.

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.

Uncertainty in Calibration, Detection and Estimation of Metal Concentrations in Engine Plumes Using OPAD

NASA Technical Reports Server (NTRS)

Hopkins, Randall C.; Benzing, Daniel A.

1998-01-01

Improvements in uncertainties in the values of radiant intensity (I) can be accomplished mainly by improvements in the calibration process and in minimizing the difference between the background and engine plume radiance. For engine tests in which the plume is extremely bright, the difference in luminance between the calibration lamp and the engine plume radiance can be so large as to cause relatively large uncertainties in the values of R. This is due to the small aperture necessary on the receiving optics to avoid saturating the instrument. However, this is not a problem with the SSME engine since the liquid oxygen/hydrogen combustion is not as bright as some other fuels. Applying the instrumentation to other type engine tests may require a much brighter calibration lamp.

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.

Smart and Intelligent Sensors

NASA Technical Reports Server (NTRS)

Lansaw, John; Schmalzel, John; Figueroa, Jorge

2009-01-01

John C. Stennis Space Center (SSC) provides rocket engine propulsion testing for NASA's space programs. Since the development of the Space Shuttle, every Space Shuttle Main Engine (SSME) has undergone acceptance testing at SSC before going to Kennedy Space Center (KSC) for integration into the Space Shuttle. The SSME is a large cryogenic rocket engine that uses Liquid Hydrogen (LH2) as the fuel. As NASA moves to the new ARES V launch system, the main engines on the new vehicle, as well as the upper stage engine, are currently base lined to be cryogenic rocket engines that will also use LH2. The main rocket engines for the ARES V will be larger than the SSME, while the upper stage engine will be approximately half that size. As a result, significant quantities of hydrogen will be required during the development, testing, and operation of these rocket engines.Better approaches are needed to simplify sensor integration and help reduce life-cycle costs. 1.Smarter sensors. Sensor integration should be a matter of "plug-and-play" making sensors easier to add to a system. Sensors that implement new standards can help address this problem; for example, IEEE STD 1451.4 defines transducer electronic data sheet (TEDS) templates for commonly used sensors such as bridge elements and thermocouples. When a 1451.4 compliant smart sensor is connected to a system that can read the TEDS memory, all information needed to configure the data acquisition system can be uploaded. This reduces the amount of labor required and helps minimize configuration errors. 2.Intelligent sensors. Data received from a sensor be scaled, linearized; and converted to engineering units. Methods to reduce sensor processing overhead at the application node are needed. Smart sensors using low-cost microprocessors with integral data acquisition and communication support offer the means to add these capabilities. Once a processor is embedded, other features can be added; for example, intelligent sensors can make a health assessment to inform the data acquisition client when sensor performance is suspect. 3.Distributed sample synchronization. Networks of sensors require new ways for synchronizing samples. Standards that address the distributed timing problem (for example, IEEE STD 1588) provide the means to aggregate samples from many distributed smart sensors with sub-microsecond accuracy. 4. Reduction in interconnect. Alternative means are needed to reduce the frequent problems associated with cabling and connectors. Wireless technologies offer the promise of reducing interconnects and simultaneously making it easy to quickly add a sensor to a system.

High-Speed Observer: Automated Streak Detection in SSME Plumes

NASA Technical Reports Server (NTRS)

Rieckoff, T. J.; Covan, M.; OFarrell, J. M.

2001-01-01

A high frame rate digital video camera installed on test stands at Stennis Space Center has been used to capture images of Space Shuttle main engine plumes during test. These plume images are processed in real time to detect and differentiate anomalous plume events occurring during a time interval on the order of 5 msec. Such speed yields near instantaneous availability of information concerning the state of the hardware. This information can be monitored by the test conductor or by other computer systems, such as the integrated health monitoring system processors, for possible test shutdown before occurrence of a catastrophic engine failure.

Heat flux measurement in SSME turbine blade tester

NASA Astrophysics Data System (ADS)

Liebert, Curt H.

1990-11-01

Surface heat flux values were measured in the turbine blade thermal cycling tester located at NASA-Marshall. This is the first time heat flux has been measured in a space shuttle main engine turbopump environment. Plots of transient and quasi-steady state heat flux data over a range of about 0 to 15 MW/sq m are presented. Data were obtained with a miniature heat flux gage device developed at NASA-Lewis. The results from these tests are being incorporated into turbine design models. Also, these gages are being considered for airfoil surface heat flux measurement on turbine vanes mounted in SSME turbopump test bed engine nozzles at Marshall. Heat flux effects that might be observed on degraded vanes are discussed.

Heat flux measurement in SSME turbine blade tester

NASA Astrophysics Data System (ADS)

Liebert, Curt H.

Surface heat flux values were measured in the turbine blade thermal cycling tester located at NASA-Marshall. This is the first time heat flux has been measured in a space shuttle main engine turbopump environment. Plots of transient and quasi-steady state heat flux data over a range of about 0 to 15 MW/sq m are presented. Data were obtained with a miniature heat flux gage device developed at NASA-Lewis. The results from these tests are being incorporated into turbine design models. Also, these gages are being considered for airfoil surface heat flux measurement on turbine vanes mounted in SSME turbopump test bed engine nozzles at Marshall. Heat flux effects that might be observed on degraded vanes are discussed.

KSC-2013-3238

NASA Image and Video Library

2013-08-09

CAPE CANAVERAL, Fla. – As seen on Google Maps, a Space Shuttle Main Engine, or SSME, stands inside the Engine Shop at Orbiter Processing Facility 3 at NASA's Kennedy Space Center. Each orbiter used three of the engines during launch and ascent into orbit. The engines burn super-cold liquid hydrogen and liquid oxygen and each one produces 155,000 pounds of thrust. The engines, known in the industry as RS-25s, could be reused on multiple shuttle missions. They will be used again later this decade for NASA's Space Launch System rocket. Google precisely mapped the space center and some of its historical facilities for the company's map page. The work allows Internet users to see inside buildings at Kennedy as they were used during the space shuttle era. Photo credit: Google/Wendy Wang

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.

Cold flow testing of the Space Shuttle Main Engine high pressure fuel turbine model

NASA Technical Reports Server (NTRS)

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

1991-01-01

In order to experimentally determine the performance of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) turbine, a 'cold' air flow turbine test program was established at NASA's Marshall Space Flight Center. As part of this test program, a baseline test of Rocketdyne's HPFTP turbine has been completed. The turbine performance and turbine diagnostics such as airfoil surface static pressure distributions, static pressure drops through the turbine, and exit swirl angles were investigated at the turbine design point, over its operating range, and at extreme off-design points. The data was compared to pretest predictions with good results. The test data has been used to improve meanline prediction codes and is now being used to validate various three-dimensional codes. The data will also be scaled to engine conditions and used to improve the SSME steady-state performance model.

Parallel Unsteady Turbopump Simulations for Liquid Rocket Engines

NASA Technical Reports Server (NTRS)

Kiris, Cetin C.; Kwak, Dochan; Chan, William

2000-01-01

This paper reports the progress being made towards complete turbo-pump simulation capability for liquid rocket engines. Space Shuttle Main Engine (SSME) turbo-pump impeller is used as a test case for the performance evaluation of the MPI and hybrid MPI/Open-MP versions of the INS3D code. Then, a computational model of a turbo-pump has been developed for the shuttle upgrade program. Relative motion of the grid system for rotor-stator interaction was obtained by employing overset grid techniques. Time-accuracy of the scheme has been evaluated by using simple test cases. Unsteady computations for SSME turbo-pump, which contains 136 zones with 35 Million grid points, are currently underway on Origin 2000 systems at NASA Ames Research Center. Results from time-accurate simulations with moving boundary capability, and the performance of the parallel versions of the code will be presented in the final paper.

An evaluation of GTAW-P versus GTA welding of alloy 718

NASA Technical Reports Server (NTRS)

Gamwell, W. R.; Kurgan, C.; Malone, T. W.

1991-01-01

Mechanical properties were evaluated to determine statistically whether the pulsed current gas tungsten arc welding (GTAW-P) process produces welds in alloy 718 with room temperature structural performance equivalent to current Space Shuttle Main Engine (SSME) welds manufactured by the constant current GTAW-P process. Evaluations were conducted on two base metal lots, two filler metal lots, two heat input levels, and two welding processes. The material form was 0.125-inch (3.175-mm) alloy 718 sheet. Prior to welding, sheets were treated to either the ST or STA-1 condition. After welding, panels were left as welded or heat treated to the STA-1 condition, and weld beads were left intact or machined flush. Statistical analyses were performed on yield strength, ultimate tensile strength (UTS), and high cycle fatigue (HCF) properties for all the post welded material conditions. Analyses of variance were performed on the data to determine if there were any significant effects on UTS or HCF life due to variations in base metal, filler metal, heat input level, or welding process. Statistical analyses showed that the GTAW-P process does produce welds with room temperature structural performance equivalent to current SSME welds manufactured by the GTAW process, regardless of prior material condition or post welding condition.

Analysis of physical-chemical processes governing SSME internal fluid flows

NASA Technical Reports Server (NTRS)

Singhal, A. K.; Owens, S. F.; Mukerjee, T.; Keeton, L. W.; Prakash, C.; Przekwas, A. J.

1984-01-01

The efforts to adapt CHAM's computational fluid dynamics code, PHOENICS, to the analysis of flow within the high pressure fuel turbopump (HPFTP) aft-platform seal cavity of the SSME are summarized. In particular, the special purpose PHOENICS satellite and ground station specifically formulated for this application are listed and described, and the preliminary results of the first part two-dimensional analyses are presented and discussed. Planned three-dimensional analyses are also briefly outlined. To further understand the mixing and combustion processes in the SSME fuelside preburners, a single oxygen-hydrogen jet element was investigated.

SSME alternate turbopump (pump section) axial load analysis

NASA Technical Reports Server (NTRS)

Crease, G. A.; Rosello, A., Jr.; Fetfatsidis, A. K.

1989-01-01

A flow balancing computer program constructed to calculate the axial loads on the Space Shuttle Main Engine (SSME) alternate turbopumps (ATs) pump sections are described. The loads are used in turn to determine load balancing piston design requirements. The application of the program to the inlet section, inducer/impeller/stage, bearings, seals, labyrinth, damper, piston, face and corner, and stationary/rotating surfaces is indicated. Design analysis results are reported which show that the balancing piston's designs are adequate and that performance and life will not be degraded by the turbopump's axial load characteristics.

Flow induced vibrations in the SSME injector heads

NASA Technical Reports Server (NTRS)

Lepore, Frank A.

1991-01-01

A description is given of the flowfield in the Space Shuttle Main Engine (SSME) powerhead, the mechanisms which control flow-induced vibrations, and previous experimental work. An in-depth description is given of the development phase of the program , which includes the analysis, design, and fabrication of liquid oxygen (LOX) posts models used in the experimental phase, as well as test facilities, equipment, and procedures used. Also covered is the experimental data analysis, which includes overall steady state powerhead flowfield as well as the high frequency response of the LOX posts.

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.

Calibrator tests of heat flux gauges mounted in SSME blades

NASA Technical Reports Server (NTRS)

Liebert, Curt H.

1989-01-01

Measurements of heat flux to space shuttle main engine (SSME) turbine blade surfaces are being made in the Lewis heat flux calibration facility. Surface heat flux information is obtained from transient temperature measurements taken at points within the gauge. A 100-kW Vortek arc lamp is used as a source of thermal radiant energy. Thermoplugs, with diameters of about 0.190 cm and lengths varying from about 0.190 to 0.320 cm, are being investigated. The thermoplug is surrounded on all surfaces except the active surface by a pocket of air located in the circular annulus and under the back cover. Since the thermoplug is insulated, it is assumed that heat is conducted in a one-dimensional manner from the hot active surface to the cooler back side of the thermoplug. It is concluded that the miniature plug-type gauge concept is feasible for measurement of blade surface heat flux. It is suggested that it is important to measure heat flux near the hub on the suction surface and at the throat on SSME blades rotating in engines because stress and heat transfer coefficients are high in this region.

Analysis of space shuttle main engine data using Beacon-based exception analysis for multi-missions

NASA Technical Reports Server (NTRS)

Park, H.; Mackey, R.; James, M.; Zak, M.; Kynard, M.; Sebghati, J.; Greene, W.

2002-01-01

This paper describes analysis of the Space Shuttle Main Engine (SSME) sensor data using Beacon-based exception analysis for multimissions (BEAM), a new technology developed for sensor analysis and diagnostics in autonomous space systems by the Jet Propulsion Laboratory (JPL).

Space Shuttle Main Engine (SSME) Evolution

NASA Technical Reports Server (NTRS)

Worlund, Len A.; Hastings, J. H.; McCool, Alex (Technical Monitor)

2001-01-01

The SSME when developed in the 1970's was a technological leap in space launch propulsion system design. The engine has safely supported the space shuttle for the last two decades and will be required for at least another decade to support human space flight to the international space station. This paper discusses the continued improvements and maturing of the system to its current state and future considerations for its critical role in the nations space program. Discussed are the initiatives of the late 1980's, which lead to three major upgrades through the 1990's. The current capabilities of the propulsion system are defined in the areas of highest programmatic importance: ascent risk, in-flight abort thrust, reusability, and operability. Future initiatives for improved shuttle safety, the paramount priority of the Space Shuttle program are discussed.

VPS GRCop-84 Liner Development Efforts

NASA Technical Reports Server (NTRS)

Elam, Sandra K.; Holmes, Richard; McKechnie, Tim; Hickman, Robert; Pickens, Tim

2003-01-01

For the past several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc. (PPI) to fabricate combustion chamber liners using the Vacuum Plasma Spray (VPS) process. Multiple liners of a variety of shapes and sizes have been created. Each liner has been fabricated with GRCop-84 (a copper alloy with chromium and niobium) and a functional gradient coating (FGC) on the hot wall. While the VPS process offers versatility and a reduced fabrication schedule, the material system created with VPS allows the liners to operate at higher temperatures, with maximum blanch resistance and improved cycle life. A subscal unit (5K lbf thrust class) is being cycle tested in a LOX/Hydrogen thrust chamber assembly at MSFC. To date, over 75 hot-fire tests have been accumulated on this article. Tests include conditions normally detrimental to conventional materials, yet the VPS GRCop-84 liner has yet to show any signs of degradation. A larger chamber (15K lbf thrust class) has also been fabricated and is being prepared for hot-fire testing at MSFC near the end of 2003. Linear liners have been successfully created to further demonstrate the versatility of the process. Finally, scale up issues for the VPS process are being tackled with efforts to fabricate a full size, engine class liner. Specifically, a liner for the SSME's Main Combustion Chamber (MCC) has recently been attempted. The SSME size was chosen for convenience, since its design was readily available and its size was sufficient to tackle specific issues. Efforts to fabricate these large liners have already provided valuable lessons for using this process for engine programs. The material quality for these large units is being evaluated with destructive analysis and these results will be available by the end of 2003.

Final Prep on SSME

NASA Image and Video Library

2005-10-25

Alvin Pittman Sr., lead electronics technician with Pratt & Whitney Rocketdyne, and Janine Cuevas, a mechanical technician with PWR, perform final preparations on the space shuttle main engine tested Oct. 25, 2005, at NASA's Stennis Space Center. It was the first main engine test since Hurricane Katrina hit the Gulf Coast on Aug. 29.

Final Prep on SSME

NASA Technical Reports Server (NTRS)

2005-01-01

Alvin Pittman Sr., lead electronics technician with Pratt & Whitney Rocketdyne, and Janine Cuevas, a mechanical technician with PWR, perform final preparations on the space shuttle main engine tested Oct. 25, 2005, at NASA's Stennis Space Center. It was the first main engine test since Hurricane Katrina hit the Gulf Coast on Aug. 29.

Reusable rocket engine turbopump condition monitoring

NASA Technical Reports Server (NTRS)

Hampson, M. E.

1984-01-01

Significant improvements in engine readiness with reductions in maintenance costs and turn-around times can be achieved with an engine condition monitoring systems (CMS). The CMS provides health status of critical engine components, without disassembly, through monitoring with advanced sensors. Engine failure reports over 35 years were categorized into 20 different modes of failure. Rotor bearings and turbine blades were determined to be the most critical in limiting turbopump life. Measurement technologies were matched to each of the failure modes identified. Three were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiberoptic deflectometer (bearings), and the fiberoptic pyrometer (blades). Signal processing algorithms were evaluated for their ability to provide useful health data to maintenance personnel. Design modifications to the Space Shuttle Main Engine (SSME) high pressure turbopumps were developed to incorporate the sensors. Laboratory test fixtures have been designed for monitoring the rotor bearings and turbine blades in simulated turbopump operating conditions.

Man-machine interface and control of the shuttle digital flight system

NASA Technical Reports Server (NTRS)

Burghduff, R. D.; Lewis, J. L., Jr.

1985-01-01

The space shuttle main engine (SSME) presented new requirements in the design of controls for large pump fed liquid rocket engine systems. These requirements were the need for built in full mission support capability, and complexity and flexibility of function not previously needed in this type of application. An engine mounted programmable digital control system was developed to meet these requirements. The engine system and controller and their function are described. Design challenges encountered during the course of development included accommodation for a very severe engine environment, the implementation of redundancy and redundancy management to provide fail operational/fail safe capability, removal of heat from the package, and significant constraints on computer memory size and processing time. The flexibility offered by programmable control reshaped the approach to engine design and development and set the pattern for future controls development in these types of applications.

Advanced main combustion chamber program

NASA Technical Reports Server (NTRS)

1991-01-01

The topics presented are covered in viewgraph form and include the following: investment of low cost castings; usage of SSME program; usage of MSFC personnel for design effort; and usage of concurrent engineering techniques.

Structural Integrity and Durability of Reusable Space Propulsion Systems

NASA Technical Reports Server (NTRS)

1991-01-01

A two-day conference on the structural integrity and durability of reusable space propulsion systems was held on 14 to 15 May 1991 at the NASA Lewis Research Center. Presentations were made by industry, university, and government researchers organized into four sessions: (1) aerothermodynamic loads; (2) instrumentation; (3) fatigue, fracture, and constitutive modeling; and (4) structural dynamics. The principle objectives were to disseminate research results and future plans in each of four areas. This publication contains extended abstracts and the visual material presented during the conference. Particular emphasis is placed on the Space Shuttle Main Engine (SSME) and the SSME turbopump.

Duct flow nonuniformities: Effect of struts in SSME HGM 2+

NASA Technical Reports Server (NTRS)

Burke, Roger

1988-01-01

This study consists of an analysis of flow through the Space Shuttle Main Engine (SSME) Hot Gas Manifold (HGM) for the purpose of understanding and quantifying the flow environment and, in particular, the flow through a region of structural supports located between the inner and outer walls of the HGM. The primary task of the study, as defined by NASA-MSFC, is to assess and develop the computational capability for analyzing detailed three-dimensional flow through the HGM support strut region to be incorporated into a full fuelside HGM analysis. Secondarily, computed results are to be compared with available experimental results.

Evaluation of shuttle turbopump bearings

NASA Technical Reports Server (NTRS)

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

1978-01-01

Because the high pressure turbopumps used on the space shuttle main engine (SSME) are high speed machines and rotor dynamics analysis of these units is very complicated, it was considered necessary to verify calculated turbomachinery shaft bearing loads by analysis of ball bearing load tracks. This report presents the methods used and the results of load track analysis on one set of bearings removed from a high pressure liquid oxygen turbopump which had been subjected to SSME static firing tests. This type of analysis was found useful in determining bearing operating conditions and for verifying rotor dynamics computer models.

An Assessment Methodology to Evaluate In-Flight Engine Health Management Effectiveness

NASA Astrophysics Data System (ADS)

Maggio, Gaspare; Belyeu, Rebecca; Pelaccio, Dennis G.

2002-01-01

flight effectiveness of candidate engine health management system concepts. A next generation engine health management system will be required to be both reliable and robust in terms of anomaly detection capability. The system must be able to operate successfully in the hostile, high-stress engine system environment. This implies that its system components, such as the instrumentation, process and control, and vehicle interface and support subsystems, must be highly reliable. Additionally, the system must be able to address a vast range of possible engine operation anomalies through a host of different types of measurements supported by a fast algorithm/architecture processing capability that can identify "true" (real) engine operation anomalies. False anomaly condition reports for such a system must be essentially eliminated. The accuracy of identifying only real anomaly conditions has been an issue with the Space Shuttle Main Engine (SSME) in the past. Much improvement in many of the technologies to address these areas is required. The objectives of this study were to identify and demonstrate a consistent assessment methodology that can evaluate the capability of next generation engine health management system concepts to respond in a correct, timely manner to alleviate an operational engine anomaly condition during flight. Science Applications International Corporation (SAIC), with support from NASA Marshall Space Flight Center, identified a probabilistic modeling approach to assess engine health management system concept effectiveness using a deterministic anomaly-time event assessment modeling approach that can be applied in the engine preliminary design stage of development to assess engine health management system concept effectiveness. Much discussion in this paper focuses on the formulation and application approach in performing this assessment. This includes detailed discussion of key modeling assumptions, the overall assessment methodology approach identified, and the identification of key supporting engine health management system concept design/operation and fault mode information required to utilize this methodology. At the paper's conclusion, discussion focuses on a demonstration benchmark study that applied this methodology to the current SSME health management system. A summary of study results and lessons learned are provided. Recommendations for future work in this area are also identified at the conclusion of the paper. * Please direct all correspondence/communication pertaining to this paper to Dennis G. Pelaccio, Science

Reusable Rocket Engine Advanced Health Management System. Architecture and Technology Evaluation: Summary

NASA Technical Reports Server (NTRS)

Pettit, C. D.; Barkhoudarian, S.; Daumann, A. G., Jr.; Provan, G. M.; ElFattah, Y. M.; Glover, D. E.

1999-01-01

In this study, we proposed an Advanced Health Management System (AHMS) functional architecture and conducted a technology assessment for liquid propellant rocket engine lifecycle health management. The purpose of the AHMS is to improve reusable rocket engine safety and to reduce between-flight maintenance. During the study, past and current reusable rocket engine health management-related projects were reviewed, data structures and health management processes of current rocket engine programs were assessed, and in-depth interviews with rocket engine lifecycle and system experts were conducted. A generic AHMS functional architecture, with primary focus on real-time health monitoring, was developed. Fourteen categories of technology tasks and development needs for implementation of the AHMS were identified, based on the functional architecture and our assessment of current rocket engine programs. Five key technology areas were recommended for immediate development, which (1) would provide immediate benefits to current engine programs, and (2) could be implemented with minimal impact on the current Space Shuttle Main Engine (SSME) and Reusable Launch Vehicle (RLV) engine controllers.

Probabilistic structural analysis of space propulsion system LOX post

NASA Technical Reports Server (NTRS)

Newell, J. F.; Rajagopal, K. R.; Ho, H. W.; Cunniff, J. M.

1990-01-01

The probabilistic structural analysis program NESSUS (Numerical Evaluation of Stochastic Structures Under Stress; Cruse et al., 1988) is applied to characterize the dynamic loading and response of the Space Shuttle main engine (SSME) LOX post. The design and operation of the SSME are reviewed; the LOX post structure is described; and particular attention is given to the generation of composite load spectra, the finite-element model of the LOX post, and the steps in the NESSUS structural analysis. The results are presented in extensive tables and graphs, and it is shown that NESSUS correctly predicts the structural effects of changes in the temperature loading. The probabilistic approach also facilitates (1) damage assessments for a given failure model (based on gas temperature, heat-shield gap, and material properties) and (2) correlation of the gas temperature with operational parameters such as engine thrust.

Fluid Flow Technology that Measures Up

NASA Technical Reports Server (NTRS)

2004-01-01

From 1994 to 1996, NASA s Marshall Space Flight Center conducted a Center Director's Discretionary Fund research effort to apply artificial intelligence technologies to the health management of plant equipment and space propulsion systems. Through this effort, NASA established a business relationship with Quality Monitoring and Control (QMC), of Kingwood, Texas, to provide hardware modeling and artificial intelligence tools. Very detailed and accurate Space Shuttle Main Engine (SSME) analysis and algorithms were jointly created, which identified several missing, critical instrumentation needs for adequately evaluating the engine health status. One of the missing instruments was a liquid oxygen (LOX) flow measurement. This instrument was missing since the original SSME included a LOX turbine flow meter that failed during a ground test, resulting in considerable damage for NASA. New balanced flow meter technology addresses this need with robust, safe, and accurate flow metering hardware.

Automated Test Environment for a Real-Time Control System

NASA Technical Reports Server (NTRS)

Hall, Ronald O.

1994-01-01

An automated environment with hardware-in-the-loop has been developed by Rocketdyne Huntsville for test of a real-time control system. The target system of application is the man-rated real-time system which controls the Space Shuttle Main Engines (SSME). The primary use of the environment is software verification and validation, but it is also useful for evaluation and analysis of SSME avionics hardware and mathematical engine models. It provides a test bed for the integration of software and hardware. The principles and skills upon which it operates may be applied to other target systems, such as those requiring hardware-in-the-loop simulation and control system development. Potential applications are in problem domains demanding highly reliable software systems requiring testing to formal requirements and verifying successful transition to/from off-nominal system states.

Failure Control Techniques for the SSME

NASA Technical Reports Server (NTRS)

Taniguchi, M. H.

1987-01-01

Since ground testing of the Space Shuttle Main Engine (SSME) began in 1975, the detection of engine anomalies and the prevention of major damage have been achieved by a multi-faceted detection/shutdown system. The system continues the monitoring task today and consists of the following: sensors, automatic redline and other limit logic, redundant sensors and controller voting logic, conditional decision logic, and human monitoring. Typically, on the order of 300 to 500 measurements are sensed and recorded for each test, while on the order of 100 are used for control and monitoring. Despite extensive monitoring by the current detection system, twenty-seven (27) major incidents have occurred. This number would appear insignificant compared with over 1200 hot-fire tests which have taken place since 1976. However, the number suggests the requirement for and future benefits of a more advanced failure detection system.

Dynamic characteristics of single crystal SSME blades

NASA Technical Reports Server (NTRS)

Moss, L. A.; Smith, T. E.

1987-01-01

The Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) blades are currently manufactured using a directionally solidified (DS) material, MAR-M-246+Hf. However, a necessity to reduce the occurrence of fatigue cracking within the DS blades has lead to an interest in the use of a single crystal (SC) material, PWA-1480. A study was initiated to determine the dynamic characteristics of the HPFTP blades made of SC material and find possible critical engine order excitations. This study examined both the first and second stage drive turbine blades of the HPFTP. The dynamic characterization was done analytically as well as experimentally. The analytical study examined the SC first stage HPFTP blade dynamic characteristics under typical operating conditions. The blades were analyzed using MSC/NASTRAN and a finite element model. Two operating conditions, 27500 RPM and 35000 RPM, were investigated.

SSME lifetime prediction and verification, integrating environments, structures, materials: The challenge

NASA Technical Reports Server (NTRS)

Ryan, R. S.; Salter, L. D.; Young, G. M., III; Munafo, P. M.

1985-01-01

The planned missions for the space shuttle dictated a unique and technology-extending rocket engine. The high specific impulse requirements in conjunction with a 55-mission lifetime, plus volume and weight constraints, produced unique structural design, manufacturing, and verification requirements. Operations from Earth to orbit produce severe dynamic environments, which couple with the extreme pressure and thermal environments associated with the high performance, creating large low cycle loads and high alternating stresses above endurance limit which result in high sensitivity to alternating stresses. Combining all of these effects resulted in the requirements for exotic materials, which are more susceptible to manufacturing problems, and the use of an all-welded structure. The challenge of integrating environments, dynamics, structures, and materials into a verified SSME structure is discussed. The verification program and developmental flight results are included. The first six shuttle flights had engine performance as predicted with no failures. The engine system has met the basic design challenges.

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.

Application of dual-fuel propulsion to a single stage AMLS vehicle

NASA Technical Reports Server (NTRS)

Lepsch, Roger A., Jr.; Stanley, Douglas O.; Unal, Resit

1993-01-01

As part of NASA's Advanced Manned Launch System (AMLS) study to determine a follow-on, or complement, to the Space Shuttle, a reusable single-stage-to-orbit concept utilizing dual-fuel rocket propulsion has been examined. Several dual-fuel propulsion concepts were investigated. These include: a separate engine concept combining Russian RD-170 kerosene-fueled engines with SSME-derivative engines; the kerosene and hydrogen-fueled Russian RD-701 engine concept; and a dual-fuel, dual-expander engine concept. Analysis to determine vehicle weight and size characteristics was performed using conceptual level design techniques. A response surface methodology for multidisciplinary design was utilized to optimize the dual-fuel vehicle concepts with respect to several important propulsion system and vehicle design parameters in order to achieve minimum empty weight. Comparisons were then made with a hydrogen-fueled reference, single-stage vehicle. The tools and methods employed in the analysis process are also summarized.

Cryostatless high temperature supercurrent bearings for rocket engine turbopumps

NASA Technical Reports Server (NTRS)

Rao, Dantam K.; Dill, James F.

1989-01-01

The rocket engine systems examined include SSME, ALS, and CTV systems. The liquid hydrogen turbopumps in the SSME and ALS vehicle systems are identified as potentially attractive candidates for development of Supercurrent Bearings since the temperatures around the bearings is about 30 K, which is considerably lower than the 95 K transition temperatures of HTS materials. At these temperatures, the current HTS materials are shown to be capable of developing significantly higher current densities. This higher current density capability makes the development of supercurrent bearings for rocket engines an attractive proposition. These supercurrent bearings are also shown to offer significant advantages over conventional bearings used in rocket engines. They can increase the life and reliability over rolling element bearings because of noncontact operation. They offer lower power loss over conventional fluid film bearings. Compared to conventional magnetic bearings, they can reduce the weight of controllers significantly, and require lower power because of the use of persistent currents. In addition, four technology areas that require further attention have been identified. These are: Supercurrent Bearing Conceptual Design Verification; HTS Magnet Fabrication and Testing; Cryosensors and Controller Development; and Rocket Engine Environmental Compatibility Testing.

Reusable Rocket Engine Operability Modeling and Analysis

NASA Technical Reports Server (NTRS)

Christenson, R. L.; Komar, D. R.

1998-01-01

This paper describes the methodology, model, input data, and analysis results of a reusable launch vehicle engine operability study conducted with the goal of supporting design from an operations perspective. Paralleling performance analyses in schedule and method, this requires the use of metrics in a validated operations model useful for design, sensitivity, and trade studies. Operations analysis in this view is one of several design functions. An operations concept was developed given an engine concept and the predicted operations and maintenance processes incorporated into simulation models. Historical operations data at a level of detail suitable to model objectives were collected, analyzed, and formatted for use with the models, the simulations were run, and results collected and presented. The input data used included scheduled and unscheduled timeline and resource information collected into a Space Transportation System (STS) Space Shuttle Main Engine (SSME) historical launch operations database. Results reflect upon the importance not only of reliable hardware but upon operations and corrective maintenance process improvements.

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.

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.

Rotor Re-Design for the SSME Fuel Flowmeter

NASA Technical Reports Server (NTRS)

Marcu, Bogdan

1999-01-01

The present report describes the process of redesigning a new rotor for the SSME Fuel Flowmeter. The new design addresses the specific requirement of a lower rotor speed which would allow the SSME operation at 1 15% rated power level without reaching a blade excitation by the wakes behind the hexagonal flow straightener upstream at frequencies close to the blade natural frequency. A series of calculations combining fleet flowmeters test data, airfoil fluid dynamics and CFD simulations of flow patterns behind the flowmeter's hexagonal straightener has led to a blade twist design alpha = alpha (radius) targeting a kf constant of 0.8256. The kf constant relates the fuel volume flow to the flowmeter rotor speed, for this particular value 17685 GPM at 3650 RPM. Based on this angle distribution, two actual blade designs were developed. A first design using the same blade airfoil as the original design targeted the new kf value only. A second design using a variable blade chord length and airfoil relative thickness targeted simultaneously the new kf value and an optimum blade design destined to provide smooth and stable operation and a significant increase in the blade natural frequency associated with the first bending mode, such that a comfortable margin could be obtained at 115% RPL. The second design is a result of a concurrent engineering process, during which several iterations were made in order to achieve a targeted blade natural frequency associated with the first bending mode of 1300 Hz. Water flow tests preliminary results indicate a kf value of 0.8179 for the f-irst design, which is within 1% of the target value. The second design rotor shows a natural frequency associated with the first bending mode of 1308 Hz, and a water-flow calibration constant of kf 0.8169.

Space shuttle requirements/configuration evolution

NASA Technical Reports Server (NTRS)

Andrews, E. P.

1991-01-01

Space Shuttle chronology; Space Shuttle comparison; Cost comparison; Performance; Program ground rules; Sizing criteria; Crew/passenger provisions; Space Shuttle Main Engine (SSME) characteristics; Space Shuttle program milestones; and Space Shuttle requirements are outlined. This presentation is represented by viewgraphs.

Analysis of SSEM Sensor Data Using BEAM

NASA Technical Reports Server (NTRS)

Zak, Michail; Park, Han; James, Mark

2004-01-01

A report describes analysis of space shuttle main engine (SSME) sensor data using Beacon-based Exception Analysis for Multimissions (BEAM) [NASA Tech Briefs articles, the two most relevant being Beacon-Based Exception Analysis for Multimissions (NPO- 20827), Vol. 26, No.9 (September 2002), page 32 and Integrated Formulation of Beacon-Based Exception Analysis for Multimissions (NPO- 21126), Vol. 27, No. 3 (March 2003), page 74] for automated detection of anomalies. A specific implementation of BEAM, using the Dynamical Invariant Anomaly Detector (DIAD), is used to find anomalies commonly encountered during SSME ground test firings. The DIAD detects anomalies by computing coefficients of an autoregressive model and comparing them to expected values extracted from previous training data. The DIAD was trained using nominal SSME test-firing data. DIAD detected all the major anomalies including blade failures, frozen sense lines, and deactivated sensors. The DIAD was particularly sensitive to anomalies caused by faulty sensors and unexpected transients. The system offers a way to reduce SSME analysis time and cost by automatically indicating specific time periods, signals, and features contributing to each anomaly. The software described here executes on a standard workstation and delivers analyses in seconds, a computing time comparable to or faster than the test duration itself, offering potential for real-time analysis.

LVQ and backpropagation neural networks applied to NASA SSME data

NASA Technical Reports Server (NTRS)

Doniere, Timothy F.; Dhawan, Atam P.

1993-01-01

Feedfoward neural networks with backpropagation learning have been used as function approximators for modeling the space shuttle main engine (SSME) sensor signals. The modeling of these sensor signals is aimed at the development of a sensor fault detection system that can be used during ground test firings. The generalization capability of a neural network based function approximator depends on the training vectors which in this application may be derived from a number of SSME ground test-firings. This yields a large number of training vectors. Large training sets can cause the time required to train the network to be very large. Also, the network may not be able to generalize for large training sets. To reduce the size of the training sets, the SSME test-firing data is reduced using the learning vector quantization (LVQ) based technique. Different compression ratios were used to obtain compressed data in training the neural network model. The performance of the neural model trained using reduced sets of training patterns is presented and compared with the performance of the model trained using complete data. The LVQ can also be used as a function approximator. The performance of the LVQ as a function approximator using reduced training sets is presented and compared with the performance of the backpropagation network.

3-D thermal analysis using finite difference technique with finite element model for improved design of components of rocket engine turbomachines for Space Shuttle Main Engine SSME

NASA Technical Reports Server (NTRS)

Sohn, Kiho D.; Ip, Shek-Se P.

1988-01-01

Three-dimensional finite element models were generated and transferred into three-dimensional finite difference models to perform transient thermal analyses for the SSME high pressure fuel turbopump's first stage nozzles and rotor blades. STANCOOL was chosen to calculate the heat transfer characteristics (HTCs) around the airfoils, and endwall effects were included at the intersections of the airfoils and platforms for the steady-state boundary conditions. Free and forced convection due to rotation effects were also considered in hollow cores. Transient HTCs were calculated by taking ratios of the steady-state values based on the flow rates and fluid properties calculated at each time slice. Results are presented for both transient plots and three-dimensional color contour isotherm plots; they were also converted into universal files to be used for FEM stress analyses.

Balancing low cost with reliable operation in the rotordynamic design of the ALS Liquid Hydrogen Fuel Turbopump

NASA Technical Reports Server (NTRS)

Greenhill, L. M.

1990-01-01

The Air Force/NASA Advanced Launch System (ALS) Liquid Hydrogen Fuel Turbopump (FTP) has primary design goals of low cost and high reliability, with performance and weight having less importance. This approach is atypical compared with other rocket engine turbopump design efforts, such as on the Space Shuttle Main Engine (SSME), which emphasized high performance and low weight. Similar to the SSME turbopumps, the ALS FTP operates supercritically, which implies that stability and bearing loads strongly influence the design. In addition, the use of low cost/high reliability features in the ALS FTP such as hydrostatic bearings, relaxed seal clearances, and unshrouded turbine blades also have a negative influence on rotordynamics. This paper discusses the analysis conducted to achieve a balance between low cost and acceptable rotordynamic behavior, to ensure that the ALS FTP will operate reliably without subsynchronous instabilities or excessive bearing loads.

Probabilistic evaluation of SSME structural components

NASA Astrophysics Data System (ADS)

Rajagopal, K. R.; Newell, J. F.; Ho, H.

1991-05-01

The application is described of Composite Load Spectra (CLS) and Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) family of computer codes to the probabilistic structural analysis of four Space Shuttle Main Engine (SSME) space propulsion system components. These components are subjected to environments that are influenced by many random variables. The applications consider a wide breadth of uncertainties encountered in practice, while simultaneously covering a wide area of structural mechanics. This has been done consistent with the primary design requirement for each component. The probabilistic application studies are discussed using finite element models that have been typically used in the past in deterministic analysis studies.

STS-38 Atlantis, OV-104, lifts off from KSC LC Pad during night launch

NASA Technical Reports Server (NTRS)

1990-01-01

STS-38 Atlantis, Orbiter Vehicle (OV) 104, lifts off from Kennedy Space Center (KSC) Launch Complex (LC) Pad at 6:48:15:0639 pm (Eastern Standard Time (EST)) for Department of Defense (DOD)-devoted mission. OV-104, atop the external tank (ET) and flanked by solid rocket boosters (SRBs), is almost clear of the launch tower which is lit up by the SRB and space shuttle main engine (SSME) firings. Spotlight equipment is silhouetted against the SRB/SSME glow in the foreground. The retracted rotating service structure (RSS) is highlighted against the evening darkness by the launch fireworks.

Investigation of SSME alternate high pressure fuel turbopump lift-off seal fluid and structural dynamic interaction

NASA Technical Reports Server (NTRS)

Elrod, David A.

1989-01-01

The Space Shuttle main engine (SSME) alternate turbopump development program (ATD) high pressure fuel turbopump (HPFTP) design utilizes an innovative lift-off seal (LOS) design that is located in close proximity to the turbine end bearing. Cooling flow exiting the bearing passes through the lift-off seal during steady state operation. The potential for fluid excitation of lift-off seal structural resonances is investigated. No fluid excitation of LOS resonances is predicted. However, if predicted LOS natural frequencies are significantly lowered by the presence of the coolant, pressure oscillations caused by synchronous whirl of the HPFTP rotor may excite a resonance.

Quantifying uncertainties in the structural response of SSME blades

NASA Technical Reports Server (NTRS)

Nagpal, Vinod K.

1987-01-01

To quantify the uncertainties associated with the geometry and material properties of a Space Shuttle Main Engine (SSME) turbopump blade, a computer code known as STAEBL was used. A finite element model of the blade used 80 triangular shell elements with 55 nodes and five degrees of freedom per node. The whole study was simulated on the computer and no real experiments were conducted. The structural response has been evaluated in terms of three variables which are natural frequencies, root (maximum) stress, and blade tip displacements. The results of the study indicate that only the geometric uncertainties have significant effects on the response. Uncertainties in material properties have insignificant effects.

Computational Fluid Dynamics (CFD) Analyses in Support of Space Shuttle Main Engine (SSME) Heat Exchanger (HX) Vane Cracking Investigation

NASA Technical Reports Server (NTRS)

Garcia, Roberto; Benjamin, Theodore G.; Cornelison, J.; Fredmonski, A. J.

1993-01-01

Integration issues involved with installing the alternate turbopump (ATP) High Pressure Oxygen Turbopump (HPOTP) into the SSME have raised questions regarding the flow in the HPOTP turnaround duct (TAD). Steady-state Navier-Stokes CFD analyses have been performed by NASA and Pratt & Whitney (P&W) to address these questions. The analyses have consisted of two-dimensional axisymmetric calculations done at Marshall Space Flight Center and three-dimensional calculations performed at P&W. These analyses have identified flowfield differences between the baseline ATP and the Rocketdyne configurations. The results show that the baseline ATP configuration represents a more severe environment to the inner HX guide vane. This vane has limited life when tested in conjunction with the ATP but infinite life when tested with the current SSME HPOTP. The CFD results have helped interpret test results and have been used to assess proposed redesigns. This paper includes details of the axisymmetric model, its results, and its contribution towards resolving the problem.

Performance predictions for an SSME configuration with an enlarged throat

NASA Technical Reports Server (NTRS)

Nickerson, G. R.; Dang, L. D.

1985-01-01

The Two Dimensional Kinetics (TDK) computer program that was recently developed for NASA was used to predict the performance of a Large Throat Configuration of the Space Shuttle Main Engine (SSME). Calculations indicate that the current design SSME contains a shock wave that is induced by the nozzle wall shape. In the Large Throat design an even stronger shock wave is predicted. Because of the presence of this shock wave, earlier performance predictions that have neglected shock wave effects have been questioned. The JANNAF thrust chamber performance prediction procedures given in a reference were applied. The analysis includes the effects of two dimensional reacting flow with a shock wave. The effects of the boundary layer with a regenatively cooled wall are also included. A Purdue computer program was used to compute axially symmetric supersonic nozzle flows with an induced shock, but is restricted to flows with a constant ratio of specific heats. Thus, the TDK program was also run with ths assumption and the results of the two programs were compared.

SRB thermal protection systems materials test results in an arc-heated nitrogen environment

NASA Technical Reports Server (NTRS)

Wojciechowski, C. J.

1979-01-01

The external surface of the Solid Rocket Booster (SRB) will experience imposed thermal and shear environments due to aerodynamic heating and radiation heating during launch, staging and reentry. This report is concerned with the performance of the various TPS materials during the staging maneuver. During staging, the wash from the Space Shuttle Main Engine (SSME) exhust plumes impose severe, short duration, thermal environments on the SRB. Five different SRB TPS materials were tested in the 1 MW Arc Plasma Generator (APG) facility. The maximum simulated heating rate obtained in the APG facility was 248 Btu/sq ft./sec, however, the test duration was such that the total heat was more than simulated. Similarly, some local high shear stress levels of 0.04 psia were not simulated. Most of the SSME plume impingement area on the SRB experiences shear stress levels of 0.02 psia and lower. The shear stress levels on the test specimens were between 0.021 and 0.008 psia. The SSME plume stagnation conditions were also simulated.

Evaluation of bearing mounting design and excessive wear phenomena

NASA Technical Reports Server (NTRS)

Kannel, J. W.

1982-01-01

The effect of bearing thermal growth on the effectiveness of the bearing preload springs on the space shuttle main engine high pressure oxygen turbopump (SSME HPTOP) were examined. The SSME HPTOP turbine end bearings, preload spring, and bearing mounting design were evaluated relative to spalling, excessive ball wear, possible thermal problems, and cage delamination. The magnitude of the thermal stresses required to cause high levels of ball wear were calculated. Plots of maximum sheer stress and maximum reversing shear versus the axial load for the 57 mm SSME HPTOP bearing were created. A plot of the bearing thermal growth versus preload spring deflection was generated. It was determined that metallic wear, rather than thermal growth, caused enlargement of the contact zone between ball and races, that high fatigue-inducing shear stresses are generated under increased loads, and that at temperatures between 100 and 150 deg C, the springs bottom out and very high loads are developed in the bearing. Allowance for adequate spring movement after assembly is recommended.

Software development to support sensor control of robot arc welding

NASA Technical Reports Server (NTRS)

Silas, F. R., Jr.

1986-01-01

The development of software for a Digital Equipment Corporation MINC-23 Laboratory Computer to provide functions of a workcell host computer for Space Shuttle Main Engine (SSME) robotic welding is documented. Routines were written to transfer robot programs between the MINC and an Advanced Robotic Cyro 750 welding robot. Other routines provide advanced program editing features while additional software allows communicatin with a remote computer aided design system. Access to special robot functions were provided to allow advanced control of weld seam tracking and process control for future development programs.

Closeup view of the aft fuselage looking forward along the ...

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

Close-up view of the aft fuselage looking forward along the approximate centerline of the Orbiter Discovery looking at the expansion nozzles of the Space Shuttle Main Engines (SSME) and the Orbiter Maneuvering System. Also in the view is the orbiter's body flap with a protective covering over the High-temperature Reusable Surface Insulation tiles on the surface facing the SSMEs. This image was taken inside the Orbiter Processing Facility at Kennedy Space Center. - Space Transportation System, Orbiter Discovery (OV-103), Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

Closeup oblique view of the aft fuselage of the Orbiter ...

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

Close-up oblique view of the aft fuselage of the Orbiter Discovery looking forward and port with the Space Shuttle Main Engines (SSME) and Orbiter Maneuvering System/Reaction Control System pods still in place. However. the heat shields have been removed from the SSMEs providing a good view toward the interior of the aft fuselage. This image was taken inside the Orbiter Processing Facility at Kennedy Space Center. - Space Transportation System, Orbiter Discovery (OV-103), Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

Closeup oblique view of the aft fuselage of the Orbiter ...

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

Close-up oblique view of the aft fuselage of the Orbiter Discovery looking forward and starboard with the Space Shuttle Main Engines (SSME) and Orbiter Maneuvering System/Reaction Control System pods removed. The openings for the SSMEs have been covered with a flexible barrier to create a positive pressure envelope inside of the aft fuselage. This image was taken inside the Orbiter Processing Facility at Kennedy Space Center. - Space Transportation System, Orbiter Discovery (OV-103), Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

Closeup oblique view of the aft fuselage of the Orbiter ...

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

Close-up oblique view of the aft fuselage of the Orbiter Discovery looking forward and starboard with the Space Shuttle Main Engines (SSME) and Orbiter Maneuvering System/Reaction Control System pods still in place. However. the heat shields have been removed from the SSMEs providing a good view toward the interior of the aft fuselage. This image was taken inside the Orbiter Processing Facility at Kennedy Space Center. - Space Transportation System, Orbiter Discovery (OV-103), Lyndon B. Johnson Space Center, 2101 NASA Parkway, Houston, Harris County, TX

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 performance and to establish acceptable life limits. During the program over a million seconds of accumulated test and flight time was achieved. Post flight inspection and assessment was a key part of assuring proper performance of the flight hardware. By the end of the program the predicted reliability had improved by a factor of four. These unique challenges, evolution of the design, and the resulting reliability will be discussed in this paper.

Duct flow nonuniformities for Space Shuttle Main Engine (SSME)

NASA Technical Reports Server (NTRS)

1988-01-01

Analytical capabilities for modeling hot gas flow on the fuel side of the Space Shuttle Main Engines are developed. Emphasis is placed on construction and documentation of a computational grid code for modeling an elliptical two-duct version of the fuel side hot gas manifold. Computational results for flow past a support strut in an annular channel are also presented.

Hotfire testing of a SSME HPOTP with an annular hydrostatic bearing

NASA Technical Reports Server (NTRS)

Nolan, Steven A.; Hibbs, Robert I.; Genge, Gary G.

1994-01-01

A new fluid film bearing package has been tested in the Space Shuttle Main Engine (SSME) High Pressure Oxygen Turbopump (HPOTP). This fluid film element functions as both the pump end bearing and the preburner pump rear wear ring seal. Most importantly, it replaces a duplex ball bearing package which has been the primary life limiting component in the turbopump. The design and predicted performance of the turbopump are reviewed. Results are presented for measured pump and bearing performance during testing on the NASA Technology Test Bed (TTB) Engine located at MSFC. The most significant results were obtained from proximity probes located in the bearing bore which revealed large subsynchronous precession at ten percent of shaft speed during engine start which subsided prior to mainstage power levels and reappeared during engine shutdown at equivalent power levels below 65% of nominal. This phenomenon has been attributed to rotating stall in the diffuser. The proximity probes also revealed the location of the bearing in the bore for different operating speeds. Pump vibration characteristics were improved as compared to pumps tested with ball bearings. After seven starts and more than 700 seconds of testing, the pump showed no signs of performance degradation.

Analysis of internal flows relative to the space shuttle main engine

NASA Technical Reports Server (NTRS)

1987-01-01

Cooperative efforts between the Lockheed-Huntsville Computational Mechanics Group and the NASA-MSFC Computational Fluid Dynamics staff has resulted in improved capabilities for numerically simulating incompressible flows generic to the Space Shuttle Main Engine (SSME). A well established and documented CFD code was obtained, modified, and applied to laminar and turbulent flows of the type occurring in the SSME Hot Gas Manifold. The INS3D code was installed on the NASA-MSFC CRAY-XMP computer system and is currently being used by NASA engineers. Studies to perform a transient analysis of the FPB were conducted. The COBRA/TRAC code is recommended for simulating the transient flow of oxygen into the LOX manifold. Property data for modifying the code to represent LOX/GOX flow was collected. The ALFA code was developed and recommended for representing the transient combustion in the preburner. These two codes will couple through the transient boundary conditions to simulate the startup and/or shutdown of the fuel preburner. A study, NAS8-37461, is currently being conducted to implement this modeling effort.

Investigation of Cleanliness Verification Techniques for Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Fritzemeier, Marilyn L.; Skowronski, Raymund P.

1994-01-01

Oxidizer propellant systems for liquid-fueled rocket engines must meet stringent cleanliness requirements for particulate and nonvolatile residue. These requirements were established to limit residual contaminants which could block small orifices or ignite in the oxidizer system during engine operation. Limiting organic residues in high pressure oxygen systems, such as in the Space Shuttle Main Engine (SSME), is particularly important. The current method of cleanliness verification for the SSME uses an organic solvent flush of the critical hardware surfaces. The solvent is filtered and analyzed for particulate matter followed by gravimetric determination of the nonvolatile residue (NVR) content of the filtered solvent. The organic solvents currently specified for use (1, 1, 1-trichloroethane and CFC-113) are ozone-depleting chemicals slated for elimination by December 1995. A test program is in progress to evaluate alternative methods for cleanliness verification that do not require the use of ozone-depleting chemicals and that minimize or eliminate the use of solvents regulated as hazardous air pollutants or smog precursors. Initial results from the laboratory test program to evaluate aqueous-based methods and organic solvent flush methods for NVR verification are provided and compared with results obtained using the current method. Evaluation of the alternative methods was conducted using a range of contaminants encountered in the manufacture of rocket engine hardware.

A critical evaluation of various methods for the analysis of flow-solid interaction in a nest of thin cylinders subjected to cross flows

NASA Technical Reports Server (NTRS)

Kim, Sang-Wook

1987-01-01

Various experimental, analytical, and numerical analysis methods for flow-solid interaction of a nest of cylinders subjected to cross flows are reviewed. A nest of cylinders subjected to cross flows can be found in numerous engineering applications including the Space Shuttle Maine Engine-Main Injector Assembly (SSME-MIA) and nuclear reactor heat exchangers. Despite its extreme importance in engineering applications, understanding of the flow-solid interaction process is quite limited and design of the tube banks are mostly dependent on experiments and/or experimental correlation equations. For future development of major numerical analysis methods for the flow-solid interaction of a nest of cylinders subjected to cross flow, various turbulence models, nonlinear structural dynamics, and existing laminar flow-solid interaction analysis methods are included.

Ceramic composites for rocket engine turbines

NASA Technical Reports Server (NTRS)

Herbell, Thomas P.; Eckel, Andrew J.

1991-01-01

The use of ceramic materials in the hot section of the fuel turbopump of advanced reusable rocket engines promises increased performance and payload capability, improved component life and economics, and greater design flexibility. Severe thermal transients present during operation of the Space Shuttle Main Engine (SSME), push metallic components to the limit of their capabilities. Future engine requirements might be even more severe. In phase one of this two-phase program, performance benefits were quantified and continuous fiber reinforced ceramic matrix composite components demonstrated a potential to survive the hostile environment of an advanced rocket engine turbopump.

Ceramic composites for rocket engine turbines

NASA Technical Reports Server (NTRS)

Herbell, Thomas P.; Eckel, Andrew J.

1991-01-01

The use of ceramic materials in the hot section of the fuel turbopump of advanced reusable rocket engines promises increased performance and payload capability, improved component life and economics, and greater design flexibility. Severe thermal transients present during operation of the Space Shuttle Main Engine (SSME), push metallic components to the limit of their capabilities. Future engine requirements might be even more severe. In phase one of this two-phase program, performance benefits were quantified and continuous fiber reinforced ceramic matrix composite components demonstrated a potential to survive the hostile environment of an advaced rocket engine turbopump.

1st SSME test of 2006

NASA Image and Video Library

2006-01-09

Water vapor surges from the flame deflector of the A-2 Test Stand at NASA's Stennis Space Center on Jan. 9 during the first space shuttle main engine test of the year. The test was an engine acceptance test of flight engine 2058. It's the first space shuttle main engine to be completely assembled at Kennedy Space Center. Objectives also included first-time (green run) tests of a high-pressure oxidizer turbo pump and an Advanced Health System Monitor engine controller. The test ran for the planned duration of 520 seconds.

FNAS/summer faculty fellowship research continuation program. Task 6: Integrated model development for liquid fueled rocket propulsion systems. Task 9: Aspects of model-based rocket engine condition monitoring and control

NASA Technical Reports Server (NTRS)

Santi, L. Michael; Helmicki, Arthur J.

1993-01-01

The objective of Phase I of this research effort was to develop an advanced mathematical-empirical model of SSME steady-state performance. Task 6 of Phase I is to develop component specific modification strategy for baseline case influence coefficient matrices. This report describes the background of SSME performance characteristics and provides a description of the control variable basis of three different gains models. The procedure used to establish influence coefficients for each of these three models is also described. Gains model analysis results are compared to Rocketdyne's power balance model (PBM).

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.

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.

Structural Integrity and Durability of Reusable Space Propulsion Systems

NASA Technical Reports Server (NTRS)

1985-01-01

The space shuttle main engine (SSME), a reusable space propulsion system, is discussed. The advances in high pressure oxygen hydrogen rocket technology are reported to establish the basic technology and to develop new analytical tools for the evaluation in reusable rocket systems.

Space Shuttle Main Engine Propellant Path Leak Detection Using Sequential Image Processing

NASA Technical Reports Server (NTRS)

Smith, L. Montgomery; Malone, Jo Anne; Crawford, Roger A.

1995-01-01

Initial research in this study using theoretical radiation transport models established that the occurrence of a leak is accompanies by a sudden but sustained change in intensity in a given region of an image. In this phase, temporal processing of video images on a frame-by-frame basis was used to detect leaks within a given field of view. The leak detection algorithm developed in this study consists of a digital highpass filter cascaded with a moving average filter. The absolute value of the resulting discrete sequence is then taken and compared to a threshold value to produce the binary leak/no leak decision at each point in the image. Alternatively, averaging over the full frame of the output image produces a single time-varying mean value estimate that is indicative of the intensity and extent of a leak. Laboratory experiments were conducted in which artificially created leaks on a simulated SSME background were produced and recorded from a visible wavelength video camera. This data was processed frame-by-frame over the time interval of interest using an image processor implementation of the leak detection algorithm. In addition, a 20 second video sequence of an actual SSME failure was analyzed using this technique. The resulting output image sequences and plots of the full frame mean value versus time verify the effectiveness of the system.

Progress in the measurement of SSME turbine heat flux with plug-type sensors

NASA Technical Reports Server (NTRS)

Liebert, Curt H.

1991-01-01

Data reduction was completed for tests of plug-type heat flux sensors (gauges) in a turbine blade thermal cycling tester (TBT) that is located at NASA/Marshall Space Flight Center, and a typical gauge is illustrated. This is the first time that heat flux has been measured in a Space Shuttle Main Engine (SSME) Turbopump Turbine environment. The development of the concept for the gauge was performed in a heat flux measurement facility at Lewis. In this facility, transient and steady state absorbed surface heat flux information was obtained from transient temperature measurements taken at points within the gauge. A schematic of the TBT is presented, and plots of the absorbed surface heat flux measured on the three blades tested in the TBT are presented. High quality heat flux values were measured on all three blades. The experiments demonstrated that reliable and durable gauges can be repeatedly fabricated into the airfoils. The experiment heat flux data are being used for verification of SSME analytical stress, boundary layer, and heat transfer design models. Other experimental results and future plans are also presented.

Development of Life Prediction Capabilities for Liquid Propellant Rocket Engines. Task 3. Sensor Data Validation and Reconstruction. Phase 1. System Architecture Study

DTIC Science & Technology

1991-06-01

Validation And Reconstruction -~ Phase 1: System Architecture Study i ".- Contract NAS 3 -25883 I - _ CR-187124 -4 Phase I Final Report,, " , I Prepared for...131 NAS 3 -25883 1.0 INTRODUCTION 1 2.0 EXECUTIVE SUMMARY 2 3.0 TECHNICAL DISCUSSION 8 3.1 Review of SSME Test Data and Validation Procedure 8 3.1.1...NAS 3 -25883 FIGURES FigureNo. e 1 Elements The Sensor Data Validation and Signal Reconstuction System 7 3 Current NASA MSFC Data Review Process 12 4

Time Dependent Simulation of Turbopump Flows

NASA Technical Reports Server (NTRS)

Kiris, Cetin C.; Kwak, Dochan; Chan, William; Williams, Robert

2001-01-01

The objective of this viewgraph presentation is to enhance incompressible flow simulation capability for developing aerospace vehicle components, especially unsteady flow phenomena associated with high speed turbo pumps. Unsteady Space Shuttle Main Engine (SSME)-rig1 1 1/2 rotations are completed for the 34.3 million grid points model. The moving boundary capability is obtained by using the DCF module. MLP shared memory parallelism has been implemented and benchmarked in INS3D. The scripting capability from CAD geometry to solution is developed. Data compression is applied to reduce data size in post processing and fluid/structure coupling is initiated.

SSME testing technology at the John C. Stennis Space Center

NASA Technical Reports Server (NTRS)

Kynard, Mike; Dill, Glenn

1991-01-01

An effective capability for testing the Space Shuttle Main Engine is described. The test complex utilizes a number of sophisticated test stands, test support facilities, and control centers to conduct development testing and flight acceptance testing at both nominal and off-nominal conditions.

Instrumentation for In-Flight SSME Rocket Engine Plume Spectroscopy

NASA Technical Reports Server (NTRS)

Madzsar, George C.; Bickford, Randall L.; Duncan, David B.

1994-01-01

This paper describes instrumentation that is under development for an in-flight demonstration of a plume spectroscopy system on the space shuttle main engine. The instrumentation consists of a nozzle mounted optical probe for observation of the plume, and a spectrometer for identification and quantification of plume content. This instrumentation, which is intended for use as a diagnostic tool to detect wear and incipient failure in rocket engines, will be validated by a hardware demonstration on the Technology Test Bed engine at the Marshall Space Flight Center.

Using neural networks to assist in OPAD data analysis

NASA Technical Reports Server (NTRS)

Whitaker, Kevin W.

1993-01-01

The space shuttle main engine (SSME) became the subject of plume emission spectroscopy in 1986 when researchers from NASA-Marshall Space Flight Center (MSFC), Arnold Engineering Development Center (AEDC), and Rocketdyne went to the SSME test stands at the NASA-Stennis Space Center and at Rocketdyne's Santa Susan Field Laboratory to optically observe the plume. Since then, plume spectral acquisitions have recorded many nominal tests and the qualitative spectral features of the SSME plume are now well established. Significant discoveries made with both wide-band and narrow-band plume emission spectroscopy systems led MSFC to promote the Optical Plume Anomaly Detection (OPAD) program with a goal of instrumenting all SSME test stands with customized spectrometer systems. A prototype OPAD system is now installed on the SSME Technology Test Bed (TTB) at MSFC. The OPAD system instrumentation consists of a broad-band, optical multiple-channel analyzer (OMA) and a narrow-band device called a polychrometer. The OMA is a high-resolution (1.5-2.0 Angstroms) 'super-spectrometer' covering the near-ultraviolet to near-infrared waveband (2800-7400 Angstroms), providing two scans per second. The polychrometer consists of sixteen narrow-band radiometers: fourteen monitoring discrete wavelengths of health and condition monitoring elements and two dedicated to monitoring background emissions. All sixteen channels are capable of providing 500 samples per second. To date, the prototype OPAD system has been used during 43 SSME firings on the TTB, collecting well over 250 megabytes of plume spectral data. One goal of OPAD data analysis is to determine interatively with the help of a computer code, SPECTRA4, developed at AEDC. Experience has shown that iteration with SPECTRA4 is an incredibly labor intensive task and not one to be performed by band. What is really needed is the 'inverse' of SPECTRA4 but the mathematical model for this inverse mapping is tenuous at best. However, the robustness of PSECTRA4 run in the 'forward' direction means that accurate input/output mappings can be obtained. If the mappings were inverted (i.e., input becomes output and output becomes input) then an 'inverse' of SPECTRA4 would be at hand but the 'model' would be specific to the data utilized and would in no way be general. Building a generalized model based upon known input/output mappings while ignoring the details of the governing physical model is possible through the use of a neural network. The research investigation described involves the development of a neural network to provide a generalized 'inverse' of SPECTRA4. The objectives of the research were to design an appropriate neural network architecture, train the network, and then evaluate its performance.

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.

STS-51 Space Shuttle Mission Report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1993-01-01

The STS-51 Space Shuttle Program Mission Report summarizes the payloads as well as the orbiter, external tank (ET), solid rocket booster (SRB), redesigned solid rocket motor (RSRM), and the space shuttle main engine (SSME) systems performance during the fifty-seventh flight of the space shuttle program and seventeenth flight of the orbiter vehicle Discovery (OV-103). In addition to the orbiter, the flight vehicle consisted of an ET designated as ET-59; three SSME's, which were designated as serial numbers 2031, 2034, and 2029 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-060. The lightweight RSRM's that were installed in each SRB were designated as 360W033A for the left SRB and 360L033B for the right SRB.

STS-49: Space shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W.

1992-01-01

The STS-49 Space Shuttle Program Mission Report contains a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and Space Shuttle main engine (SSME) subsystem performance during the forty-seventh flight of the Space Shuttle Program and the first flight of the Orbiter vehicle Endeavor (OV-105). In addition to the Endeavor vehicle, the flight vehicle consisted of an ET designated as ET-43 (LWT-36); three SSME's which were serial numbers 2030, 2015, and 2017 in positions 1, 2, and 3, respectively; and two SRB's designated as BI-050. The lightweight RSRM's installed in each SRB were designated as 360L022A for the left RSRM and 360L022B for the right RSRM.

Incipient failure detection (IFD) of SSME ball bearings

NASA Technical Reports Server (NTRS)

1982-01-01

Because of the immense noise background during the operation of a large engine such as the SSME, the relatively low level unique ball bearing signatures were often buried by the overall machine signal. As a result, the most commonly used bearing failure detection technique, pattern recognition using power spectral density (PSD) constructed from the extracted bearing signals, is rendered useless. Data enhancement techniques were carried out by using a HP5451C Fourier Analyzer. The signal was preprocessed by a Digital Audio Crop. DAC-1024I noise cancelling filter in order to estimate the desired signal corrupted by the backgound noise. Reference levels of good bearings were established. Any deviation of bearing signals from these reference levels indicate the incipient bearing failures.

Improve SSME power balance model

NASA Technical Reports Server (NTRS)

Karr, Gerald R.

1992-01-01

Effort was dedicated to development and testing of a formal strategy for reconciling uncertain test data with physically limited computational prediction. Specific weaknesses in the logical structure of the current Power Balance Model (PBM) version are described with emphasis given to the main routing subroutines BAL and DATRED. Selected results from a variational analysis of PBM predictions are compared to Technology Test Bed (TTB) variational study results to assess PBM predictive capability. The motivation for systematic integration of uncertain test data with computational predictions based on limited physical models is provided. The theoretical foundation for the reconciliation strategy developed in this effort is presented, and results of a reconciliation analysis of the Space Shuttle Main Engine (SSME) high pressure fuel side turbopump subsystem are examined.

STS-49: Space shuttle mission report

NASA Astrophysics Data System (ADS)

Fricke, Robert W.

1992-07-01

The STS-49 Space Shuttle Program Mission Report contains a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and Space Shuttle main engine (SSME) subsystem performance during the forty-seventh flight of the Space Shuttle Program and the first flight of the Orbiter vehicle Endeavor (OV-105). In addition to the Endeavor vehicle, the flight vehicle consisted of an ET designated as ET-43 (LWT-36); three SSME's which were serial numbers 2030, 2015, and 2017 in positions 1, 2, and 3, respectively; and two SRB's designated as BI-050. The lightweight RSRM's installed in each SRB were designated as 360L022A for the left RSRM and 360L022B for the right RSRM.

Automated Heat-Flux-Calibration Facility

NASA Technical Reports Server (NTRS)

Liebert, Curt H.; Weikle, Donald H.

1989-01-01

Computer control speeds operation of equipment and processing of measurements. New heat-flux-calibration facility developed at Lewis Research Center. Used for fast-transient heat-transfer testing, durability testing, and calibration of heat-flux gauges. Calibrations performed at constant or transient heat fluxes ranging from 1 to 6 MW/m2 and at temperatures ranging from 80 K to melting temperatures of most materials. Facility developed because there is need to build and calibrate very-small heat-flux gauges for Space Shuttle main engine (SSME).Includes lamp head attached to side of service module, an argon-gas-recirculation module, reflector, heat exchanger, and high-speed positioning system. This type of automated heat-flux calibration facility installed in industrial plants for onsite calibration of heat-flux gauges measuring fluxes of heat in advanced gas-turbine and rocket engines.

REIMR: A Process for Utilizing Propulsion-Oriented 'Lessons-Learned' to Mitigate Development Risk

NASA Technical Reports Server (NTRS)

Ballard, Richard O.; Brown, Kendall K.

2005-01-01

This paper is a summary overview of a study conducted a t the NASA Marshall Space Flight Center (MSFC) during the initial phases of the Space Launch Initiative (SLI) program to evaluate a large number of technical problems associated with the design, development, test, evaluation and operation of several major liquid propellant rocket engine systems (i.e., SSME, Fastrac, J-2, F-1). The results of this study was the identification of the "Fundamental Root Causes" that enabled the technical problems to manifest, and practices that can be implemented to prevent them from recurring in future engine development efforts. This paper will discus the Fundamental Root Causes, cite some examples of how the technical problems arose from them, and provide a discussion of how they can be mitigated or avoided.

Around Marshall

NASA Image and Video Library

1994-07-20

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.

Probabilistic structural analysis methods for space transportation propulsion systems

NASA Technical Reports Server (NTRS)

Chamis, C. C.; Moore, N.; Anis, C.; Newell, J.; Nagpal, V.; Singhal, S.

1991-01-01

Information on probabilistic structural analysis methods for space propulsion systems is given in viewgraph form. Information is given on deterministic certification methods, probability of failure, component response analysis, stress responses for 2nd stage turbine blades, Space Shuttle Main Engine (SSME) structural durability, and program plans. .

A parallel strategy for implementing real-time expert systems using CLIPS

NASA Technical Reports Server (NTRS)

Ilyes, Laszlo A.; Villaseca, F. Eugenio; Delaat, John

1994-01-01

As evidenced by current literature, there appears to be a continued interest in the study of real-time expert systems. It is generally recognized that speed of execution is only one consideration when designing an effective real-time expert system. Some other features one must consider are the expert system's ability to perform temporal reasoning, handle interrupts, prioritize data, contend with data uncertainty, and perform context focusing as dictated by the incoming data to the expert system. This paper presents a strategy for implementing a real time expert system on the iPSC/860 hypercube parallel computer using CLIPS. The strategy takes into consideration not only the execution time of the software, but also those features which define a true real-time expert system. The methodology is then demonstrated using a practical implementation of an expert system which performs diagnostics on the Space Shuttle Main Engine (SSME). This particular implementation uses an eight node hypercube to process ten sensor measurements in order to simultaneously diagnose five different failure modes within the SSME. The main program is written in ANSI C and embeds CLIPS to better facilitate and debug the rule based expert system.

STS-50 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W.

1992-01-01

The STS-50 Space Shuttle Program Mission Report contains a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle main engine (SSME) subsystem performance during the forty-eighth flight of the Space Shuttle Program, and the twelfth flight of the Orbiter vehicle Columbia (OV-102). In addition to the Columbia vehicle, the flight vehicle consisted of the following: an ET which was designated ET-50 (LUT-43); three SSME's which were serial numbers 2019, 2031, and 2011 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-051. The lightweight/redesigned RSRM's installed in each SRB were designated 360L024A for the left RSRM and 360M024B for the right RSRM. The primary objective of the STS-50 flight was to successfully perform the planned operations of the United States Microgravity Laboratory (USML-1) payload. The secondary objectives of this flight were to perform the operations required by the Investigations into Polymer Membrane Processing (IPMP), and the Shuttle Amateur Radio Experiment 2 (SAREX-2) payloads. An additional secondary objective was to meet the requirements of the Ultraviolet Plume Instrument (UVPI), which was flown as a payload of opportunity.

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.

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.

PRCC Aviation Students

NASA Image and Video Library

2007-01-26

Pratt & Whitney Rocketdyne's Jeff Hansell, right, explains functions of a space shuttle main engine to Pearl River Community College Aviation Maintenance Technology Program students. Christopher Bryon, left, of Bay St. Louis, Ret Tolar of Kiln, Dan Holston of Baxterville and Billy Zugg of Long Beach took a recent tour of the SSME Processing Facility and the E-1 Test Complex at Stennis Space Center in South Mississippi. The students attend class adjacent to the Stennis International Airport tarmac in Kiln, where they get hands-on experience. PRCC's program prepares students to be responsible for the inspection, repair and maintenance of technologically advanced aircraft. A contractor to NASA, Pratt & Whitney Rocketdyne in Canoga Park, Calif., manufactures the space shuttle main engine and its high-pressure turbo pumps. SSC was established in the 1960s to test the huge engines for the Saturn V moon rockets. Now 40 years later, the center tests every main engine for the space shuttle, and is America's largest rocket engine test complex. SSC will soon begin testing the rocket engines that will power spacecraft carrying Americans back to the moon and on to Mars.

PRCC Aviation Students

NASA Technical Reports Server (NTRS)

2007-01-01

Pratt & Whitney Rocketdyne's Jeff Hansell, right, explains functions of a space shuttle main engine to Pearl River Community College Aviation Maintenance Technology Program students. Christopher Bryon, left, of Bay St. Louis, Ret Tolar of Kiln, Dan Holston of Baxterville and Billy Zugg of Long Beach took a recent tour of the SSME Processing Facility and the E-1 Test Complex at Stennis Space Center in South Mississippi. The students attend class adjacent to the Stennis International Airport tarmac in Kiln, where they get hands-on experience. PRCC's program prepares students to be responsible for the inspection, repair and maintenance of technologically advanced aircraft. A contractor to NASA, Pratt & Whitney Rocketdyne in Canoga Park, Calif., manufactures the space shuttle main engine and its high-pressure turbo pumps. SSC was established in the 1960s to test the huge engines for the Saturn V moon rockets. Now 40 years later, the center tests every main engine for the space shuttle, and is America's largest rocket engine test complex. SSC will soon begin testing the rocket engines that will power spacecraft carrying Americans back to the moon and on to Mars.

STS-46 Space Shuttle mission report

NASA Astrophysics Data System (ADS)

Fricke, Robert W.

1992-10-01

The STS-46 Space Shuttle Program Mission Report contains a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle main engine (SSME) subsystem performance during the forty-ninth flight of the Space Shuttle Program, and the twelfth flight of the Orbiter vehicle Atlantis (OV-104). In addition to the Atlantis vehicle, the flight vehicle consisted of the following: an ET, designated ET-48 (LWT-41); three SSME's, which were serial numbers 2032, 2033, and 2027 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-052. The lightweight/redesigned SRM's that were installed in each SRB were designated 360W025A for the left RSRM and 360L025B for the right RSRM. The primary objective of this flight was to successfully deploy the European Retrievable Carrier (EURECA) payload and perform the operations of the Tethered Satellite System-1 (TSS-1) and the Evaluation of Oxygen Interaction with Material 3/Thermal Energy Management Processes 2A-3 (EOIM-3/TEMP 2A-3). The secondary objectives of this flight were to perform the operations of the IMAX Cargo Bay Camera (ICBC), Consortium for Material Development in Space Complex Autonomous Payload-2 and 3 (CONCAP-2 and CONCAP-3), Limited Duration Space Environment Candidate Materials Exposure (LDCE), Pituitary Growth Hormone Cell Function (PHCF), and Ultraviolet Plume Instrumentation (UVPI). In addition to summarizing subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. Also included in the discussion is a reference to the assigned tracking number as published on the Problem Tracking List. All times are given in Greenwich mean time (G.m.t.) as well as mission elapsed time (MET).

STS-46 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W.

1992-01-01

The STS-46 Space Shuttle Program Mission Report contains a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle main engine (SSME) subsystem performance during the forty-ninth flight of the Space Shuttle Program, and the twelfth flight of the Orbiter vehicle Atlantis (OV-104). In addition to the Atlantis vehicle, the flight vehicle consisted of the following: an ET, designated ET-48 (LWT-41); three SSME's, which were serial numbers 2032, 2033, and 2027 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-052. The lightweight/redesigned SRM's that were installed in each SRB were designated 360W025A for the left RSRM and 360L025B for the right RSRM. The primary objective of this flight was to successfully deploy the European Retrievable Carrier (EURECA) payload and perform the operations of the Tethered Satellite System-1 (TSS-1) and the Evaluation of Oxygen Interaction with Material 3/Thermal Energy Management Processes 2A-3 (EOIM-3/TEMP 2A-3). The secondary objectives of this flight were to perform the operations of the IMAX Cargo Bay Camera (ICBC), Consortium for Material Development in Space Complex Autonomous Payload-2 and 3 (CONCAP-2 and CONCAP-3), Limited Duration Space Environment Candidate Materials Exposure (LDCE), Pituitary Growth Hormone Cell Function (PHCF), and Ultraviolet Plume Instrumentation (UVPI). In addition to summarizing subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. Also included in the discussion is a reference to the assigned tracking number as published on the Problem Tracking List. All times are given in Greenwich mean time (G.m.t.) as well as mission elapsed time (MET).

Composite load spectra for select space propulsion structural components

NASA Technical Reports Server (NTRS)

Newell, J. F.; Ho, H. W.; Kurth, R. E.

1991-01-01

The work performed to develop composite load spectra (CLS) for the Space Shuttle Main Engine (SSME) using probabilistic methods. The three methods were implemented to be the engine system influence model. RASCAL was chosen to be the principal method as most component load models were implemented with the method. Validation of RASCAL was performed. High accuracy comparable to the Monte Carlo method can be obtained if a large enough bin size is used. Generic probabilistic models were developed and implemented for load calculations using the probabilistic methods discussed above. Each engine mission, either a real fighter or a test, has three mission phases: the engine start transient phase, the steady state phase, and the engine cut off transient phase. Power level and engine operating inlet conditions change during a mission. The load calculation module provides the steady-state and quasi-steady state calculation procedures with duty-cycle-data option. The quasi-steady state procedure is for engine transient phase calculations. In addition, a few generic probabilistic load models were also developed for specific conditions. These include the fixed transient spike model, the poison arrival transient spike model, and the rare event model. These generic probabilistic load models provide sufficient latitude for simulating loads with specific conditions. For SSME components, turbine blades, transfer ducts, LOX post, and the high pressure oxidizer turbopump (HPOTP) discharge duct were selected for application of the CLS program. They include static pressure loads and dynamic pressure loads for all four components, centrifugal force for the turbine blade, temperatures of thermal loads for all four components, and structural vibration loads for the ducts and LOX posts.

The effects of skeletal separation and moisture enhancement for improving the eating quality of cull cow beef.

PubMed

Streiter, P J; Campbell, C P; Mandell, I B

2012-12-01

Sixty-two cull beef cows were slaughtered to investigate effects of skeletal separation and moisture enhancement on beef eating quality. Muscles from each carcass side were randomly assigned to 1) no postmortem processing (NPP), 2) prerigor skeletal separation (SS), 3) moisture enhancement (ME) using calcium ascorbate or 4) a combination of SS and ME (SS/ME). Postmortem processing treatment (PPT) by ageing (PM) interactions (P<0.01) for shear force were present for longissimus. As PM ageing increased from 7 to 21 d, there was a greater decrease (P<0.05) in shear force with NPP vs. all other PPT. Trained taste panellists found SS, ME and SS/ME improved (P<0.05) palatability attributes vs. NPP. An additive effect of combining SS and ME improved palatability traits versus SS or ME alone. Panellists found no differences (P>0.14) in softness and tenderness between SS/ME and Canadian AA or AAA beef. Postmortem processing of beef cows may produce beef as tender and juicy as beef from younger carcasses. Copyright © 2012 Elsevier Ltd. All rights reserved.

NASA's CSTI Earth-to-Orbit Propulsion Program - On-target technology transfer to advanced space flight programs

NASA Technical Reports Server (NTRS)

Escher, William J. D.; Herr, Paul N.; Stephenson, Frank W., Jr.

1990-01-01

NASA's Civil Space Technology Initiative encompasses among its major elements the Earth-to-Orbit Propulsion Program (ETOPP) for future launch vehicles, which is budgeted to the extent of $20-30 million/year for the development of essential technologies. ETOPP technologies include, in addition to advanced materials and processes and design/analysis computational tools, the advanced systems-synthesis technologies required for definition of highly reliable LH2 and hydrocarbon fueled rocket engines to be operated at significantly reduced levels of risk and cost relative to the SSME. Attention is given to the technology-transfer services of ETOPP.

Sensor control of robot arc welding

NASA Technical Reports Server (NTRS)

Sias, F. R., Jr.

1985-01-01

A basic problem in the application of robots for welding which is how to guide a torch along a weld seam using sensory information was studied. Improvement of the quality and consistency of certain Gas Tungsten Arc welds on the Space Shuttle Main Engine (SSME) that are too complex geometrically for conventional automation and therefore are done by hand was examined. The particular problems associated with space shuttle main egnine (SSME) manufacturing and weld-seam tracking with an emphasis on computer vision methods were analyzed. Special interface software for the MINC computr are developed which will allow it to be used both as a test system to check out the robot interface software and later as a development tool for further investigation of sensory systems to be incorporated in welding procedures.

STS-56 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1993-01-01

The STS-56 Space Shuttle Program Mission Report provides a summary of the Payloads, as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the fifty-fourth flight of the Space Shuttle Program and sixteenth flight of the Orbiter vehicle Discovery (OV-103). In addition to the Orbiter, the flight vehicle consisted of an ET (ET-54); three SSME's, which were designated as serial numbers 2024, 2033, and 2018 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-058. The lightweight RSRM's that were installed in each SRB were designated as 360L031A for the left SRB and 360L031B for the right SRB.

SSME thrust chamber simulation using Navier-Stokes equations

NASA Technical Reports Server (NTRS)

Przekwas, A. J.; Singhal, A. K.; Tam, L. T.

1984-01-01

The capability of the PHOENICS fluid dynamics code in predicting two-dimensional, compressible, and reacting flow in the combustion chamber and nozzle of the space shuttle main engine (SSME) was evaluated. A non-orthogonal body fitted coordinate system was used to represent the nozzle geometry. The Navier-Stokes equations were solved for the entire nozzle with a turbulence model. The wall boundary conditions were calculated based on the wall functions which account for pressure gradients. Results of the demonstration test case reveal all expected features of the transonic nozzle flows. Of particular interest are the locations of normal and barrel shocks, and regions of highest temperature gradients. Calculated performance (global) parameters such as thrust chamber flow rate, thrust, and specific impulse are also in good agreement with available data.

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.

Space Shuttle Main Engine Quantitative Risk Assessment: Illustrating Modeling of a Complex System with a New QRA Software Package

NASA Technical Reports Server (NTRS)

Smart, Christian

1998-01-01

During 1997, a team from Hernandez Engineering, MSFC, Rocketdyne, Thiokol, Pratt & Whitney, and USBI completed the first phase of a two year Quantitative Risk Assessment (QRA) of the Space Shuttle. The models for the Shuttle systems were entered and analyzed by a new QRA software package. This system, termed the Quantitative Risk Assessment System(QRAS), was designed by NASA and programmed by the University of Maryland. The software is a groundbreaking PC-based risk assessment package that allows the user to model complex systems in a hierarchical fashion. Features of the software include the ability to easily select quantifications of failure modes, draw Event Sequence Diagrams(ESDs) interactively, perform uncertainty and sensitivity analysis, and document the modeling. This paper illustrates both the approach used in modeling and the particular features of the software package. The software is general and can be used in a QRA of any complex engineered system. The author is the project lead for the modeling of the Space Shuttle Main Engines (SSMEs), and this paper focuses on the modeling completed for the SSMEs during 1997. In particular, the groundrules for the study, the databases used, the way in which ESDs were used to model catastrophic failure of the SSMES, the methods used to quantify the failure rates, and how QRAS was used in the modeling effort are discussed. Groundrules were necessary to limit the scope of such a complex study, especially with regard to a liquid rocket engine such as the SSME, which can be shut down after ignition either on the pad or in flight. The SSME was divided into its constituent components and subsystems. These were ranked on the basis of the possibility of being upgraded and risk of catastrophic failure. Once this was done the Shuttle program Hazard Analysis and Failure Modes and Effects Analysis (FMEA) were used to create a list of potential failure modes to be modeled. The groundrules and other criteria were used to screen out the many failure modes that did not contribute significantly to the catastrophic risk. The Hazard Analysis and FMEA for the SSME were also used to build ESDs that show the chain of events leading from the failure mode occurence to one of the following end states: catastrophic failure, engine shutdown, or siccessful operation( successful with respect to the failure mode under consideration).

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.

THRUST AUGMENTED NOZZLE (TAN) the New Paradigm for Booster Rockets

DTIC Science & Technology

2006-07-12

station. The engine has to throttle to 34 percent (3X or 1020 psia) to keep from exceeding the acceleration limits. Figure 6. Baseline SSTO ...vehicle powered by seven up-sized SSME class engines. Figure 7. Baseline SSTO vehicle trajectory. With a payload fraction of 1 percent, it does not...want to invest in such a risky endeavor. American Institute of Aeronautics and Astronautics 6 B. TAN-Powered SSTO Vehicle For the Dual Fuel TAN

Research pressure instrumentation for NASA Space Shuttle main engine

NASA Technical Reports Server (NTRS)

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

1984-01-01

The development of prototype pressure transducers which are targeted to meet the Space Shuttle Main Engine SSME performance design goals is discussed. The fabrication, testing and delivery of 10 prototype units is examined. Silicon piezoresistive strain sensing technology is used to achieve the objectives of advanced state-of-the-art pressure sensors in terms of reliability, accuracy and ease of manufacture. Integration of multiple functions on a single chip is the key attribute of this technology.

Statistical analysis of 59 inspected SSME HPFTP turbine blades (uncracked and cracked)

NASA Technical Reports Server (NTRS)

Wheeler, John T.

1987-01-01

The numerical results of statistical analysis of the test data of Space Shuttle Main Engine high pressure fuel turbopump second-stage turbine blades, including some with cracks are presented. Several statistical methods use the test data to determine the application of differences in frequency variations between the uncracked and cracked blades.

A Monte Carlo study of Weibull reliability analysis for space shuttle main engine components

NASA Technical Reports Server (NTRS)

Abernethy, K.

1986-01-01

The incorporation of a number of additional capabilities into an existing Weibull analysis computer program and the results of Monte Carlo computer simulation study to evaluate the usefulness of the Weibull methods using samples with a very small number of failures and extensive censoring are discussed. Since the censoring mechanism inherent in the Space Shuttle Main Engine (SSME) data is hard to analyze, it was decided to use a random censoring model, generating censoring times from a uniform probability distribution. Some of the statistical techniques and computer programs that are used in the SSME Weibull analysis are described. The methods documented in were supplemented by adding computer calculations of approximate (using iteractive methods) confidence intervals for several parameters of interest. These calculations are based on a likelihood ratio statistic which is asymptotically a chisquared statistic with one degree of freedom. The assumptions built into the computer simulations are described. The simulation program and the techniques used in it are described there also. Simulation results are tabulated for various combinations of Weibull shape parameters and the numbers of failures in the samples.

Hotfire testing of a SSME HPOTP with an annular hydrostatic bearing

NASA Technical Reports Server (NTRS)

Nolan, Steven A.; Hibbs, Robert I.; Genge, Gary G.

1993-01-01

A new fluid film bearing package has been tested in the SSME High Pressure Oxygen Turbopump (HPOTP). This fluid film element functions as both the pump end bearing and the preburner pump rear wear ring seal. Most important, it replaces a duplex ball bearing package which has been the primary life limiting component in the turbopump. The design and predicted performance of the turbopump are reviewed. Results are presented for measured pump and bearing performance. The most significant results were obtained from proximity probes located in the bearing bore which revealed large subsynchronous precession at 10 percent of shaft speed during engine start which subsided prior to mainstage power levels and reappeared during engine shutdown at equivalent power levels below 65 percent of nominal. This phenomenon has been attributed to rotating stall in the diffuser. The proximity probes also revealed the location of the bearing in the bore for different operating speeds. Pump vibration characteristics were improved as compared to pumps tested with ball bearings. After seven starts and more than 700 seconds of testing, the pump showed no signs of performance degradation.

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.

RB-ARD: A proof of concept rule-based abort

NASA Technical Reports Server (NTRS)

Smith, Richard; Marinuzzi, John

1987-01-01

The Abort Region Determinator (ARD) is a console program in the space shuttle mission control center. During shuttle ascent, the Flight Dynamics Officer (FDO) uses the ARD to determine the possible abort modes and make abort calls for the crew. The goal of the Rule-based Abort region Determinator (RB/ARD) project was to test the concept of providing an onboard ARD for the shuttle or an automated ARD for the mission control center (MCC). A proof of concept rule-based system was developed on a LMI Lambda computer using PICON, a knowdedge-based system shell. Knowdedge derived from documented flight rules and ARD operation procedures was coded in PICON rules. These rules, in conjunction with modules of conventional code, enable the RB-ARD to carry out key parts of the ARD task. Current capabilities of the RB-ARD include: continuous updating of the available abort mode, recognition of a limited number of main engine faults and recommendation of safing actions. Safing actions recommended by the RB-ARD concern the Space Shuttle Main Engine (SSME) limit shutdown system and powerdown of the SSME Ac buses.

SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture

NASA Technical Reports Server (NTRS)

Ballard, Richard O.

2015-01-01

Following the cancellation of the Constellation program and retirement of the Space Shuttle, NASA initiated the Space Launch System (SLS) program to provide next-generation heavy lift cargo and crew access to space. A key constituent of the SLS architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). The RS-25 was selected to serve as the main propulsion system for the SLS core stage in conjunction with the solid rocket boosters. This selection was largely based on the maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle boat-tail and installing it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration details involving changes to significant areas such as the environments, interface conditions, technical performance requirements, operational constraints and so on, there were other challenges to be overcome in the area of replacing the obsolete engine control system (ECS). While the magnitude of accomplishing this effort was less than that needed to develop and field a new clean-sheet engine system, the path to the first flight of SLS has not been without unexpected challenges.

Enhancements to the SSME transfer function modeling code

NASA Technical Reports Server (NTRS)

Irwin, R. Dennis; Mitchell, Jerrel R.; Bartholomew, David L.; Glenn, Russell D.

1995-01-01

This report details the results of a one year effort by Ohio University to apply the transfer function modeling and analysis tools developed under NASA Grant NAG8-167 (Irwin, 1992), (Bartholomew, 1992) to attempt the generation of Space Shuttle Main Engine High Pressure Turbopump transfer functions from time domain data. In addition, new enhancements to the transfer function modeling codes which enhance the code functionality are presented, along with some ideas for improved modeling methods and future work. Section 2 contains a review of the analytical background used to generate transfer functions with the SSME transfer function modeling software. Section 2.1 presents the 'ratio method' developed for obtaining models of systems that are subject to single unmeasured excitation sources and have two or more measured output signals. Since most of the models developed during the investigation use the Eigensystem Realization Algorithm (ERA) for model generation, Section 2.2 presents an introduction of ERA, and Section 2.3 describes how it can be used to model spectral quantities. Section 2.4 details the Residue Identification Algorithm (RID) including the use of Constrained Least Squares (CLS) and Total Least Squares (TLS). Most of this information can be found in the report (and is repeated for convenience). Section 3 chronicles the effort of applying the SSME transfer function modeling codes to the a51p394.dat and a51p1294.dat time data files to generate transfer functions from the unmeasured input to the 129.4 degree sensor output. Included are transfer function modeling attempts using five methods. The first method is a direct application of the SSME codes to the data files and the second method uses the underlying trends in the spectral density estimates to form transfer function models with less clustering of poles and zeros than the models obtained by the direct method. In the third approach, the time data is low pass filtered prior to the modeling process in an effort to filter out high frequency characteristics. The fourth method removes the presumed system excitation and its harmonics in order to investigate the effects of the excitation on the modeling process. The fifth method is an attempt to apply constrained RID to obtain better transfer functions through more accurate modeling over certain frequency ranges. Section 4 presents some new C main files which were created to round out the functionality of the existing SSME transfer function modeling code. It is now possible to go from time data to transfer function models using only the C codes; it is not necessary to rely on external software. The new C main files and instructions for their use are included. Section 5 presents current and future enhancements to the XPLOT graphics program which was delivered with the initial software. Several new features which have been added to the program are detailed in the first part of this section. The remainder of Section 5 then lists some possible features which may be added in the future. Section 6 contains the conclusion section of this report. Section 6.1 is an overview of the work including a summary and observations relating to finding transfer functions with the SSME code. Section 6.2 contains information relating to future work on the project.

Investigation of the collision line broadening problem as applicable to the NASA Optical Plume Anomaly Detection (OPAD) system, phase 1

NASA Astrophysics Data System (ADS)

Dean, Timothy C.; Ventrice, Carl A.

1995-05-01

As a final report for phase 1 of the project, the researchers are submitting to the Tennessee Tech Office of Research the following two papers (reprinted in this report): 'Collision Line Broadening Effects on Spectrometric Data from the Optical Plume Anomaly System (OPAD),' presented at the 30th AIAA/ASME/SAE/ASEE Joint Propulsion Conference, 27-29 June 1994, and 'Calculation of Collision Cross Sections for Atomic Line Broadening in the Plume of the Space Shuttle Main Engine (SSME),' presented at the IEEE Southeastcon '95, 26-29 March 1995. These papers fully state the problem and the progress made up to the end of NASA Fiscal Year 1994. The NASA OPAD system was devised to predict concentrations of anomalous species in the plume of the Space Shuttle Main Engine (SSME) through analysis of spectrometric data. The self absorption of the radiation of these plume anomalies is highly dependent on the line shape of the atomic transition of interest. The Collision Line Broadening paper discusses the methods used to predict line shapes of atomic transitions in the environment of a rocket plume. The Voigt profile is used as the line shape factor since both Doppler and collisional line broadening are significant. Methods used to determine the collisional cross sections are discussed and the results are given and compared with experimental data. These collisional cross sections are then incorporated into the current self absorbing radiative model and the predicted spectrum is compared to actual spectral data collected from the Stennis Space Center Diagnostic Test Facility rocket engine. The second paper included in this report investigates an analytical method for determining the cross sections for collision line broadening by molecular perturbers, using effective central force interaction potentials. These cross sections are determined for several atomic species with H2, one of the principal constituents of the SSME plume environment, and compared with experimental data.

Crew Launch Vehicle (CLV) Upper Stage Configuration Selection Process

NASA Technical Reports Server (NTRS)

Davis, Daniel J.; Coook, Jerry R.

2006-01-01

The Crew Launch Vehicle (CLV), a key component of NASA's blueprint for the next generation of spacecraft to take humans back to the moon, is being designed and built by engineers at NASA s Marshall Space Flight Center (MSFC). The vehicle s design is based on the results of NASA's 2005 Exploration Systems Architecture Study (ESAS), which called for development of a crew-launch system to reduce the gap between Shuttle retirement and Crew Exploration Vehicle (CEV) Initial Operating Capability, identification of key technologies required to enable and significantly enhance these reference exploration systems, and a reprioritization of near- and far-term technology investments. The Upper Stage Element (USE) of the CLV is a clean-sheet approach that is being designed and developed in-house, with element management at MSFC. The USE concept is a self-supporting cylindrical structure, approximately 115' long and 216" in diameter, consisting of the following subsystems: Primary Structures (LOX Tank, LH2 Tank, Intertank, Thrust Structure, Spacecraft Payload Adaptor, Interstage, Forward and Aft Skirts), Secondary Structures (Systems Tunnel), Avionics and Software, Main Propulsion System, Reaction Control System, Thrust Vector Control, Auxiliary Power Unit, and Hydraulic Systems. The ESAS originally recommended a CEV to be launched atop a four-segment Space Shuttle Main Engine (SSME) CLV, utilizing an RS-25 engine-powered upper stage. However, Agency decisions to utilize fewer CLV development steps to lunar missions, reduce the overall risk for the lunar program, and provide a more balanced engine production rate requirement prompted engineers to switch to a five-segment design with a single Saturn-derived J-2X engine. This approach provides for single upper stage engine development for the CLV and an Earth Departure Stage, single Reusable Solid Rocket Booster (RSRB) development for the CLV and a Cargo Launch Vehicle, and single core SSME development. While the RSRB design has changed since the CLV Project's inception, the USE design has remained essentially a clean-sheet approach. Although a clean-sheet upper stage design inherently carries more risk than a modified design, it does offer many advantages: a design for increased reliability; built-in extensibility to allow for commonality/growth without major redesign; and incorporation of state-of-the-art materials, hardware, and design, fabrication, and test techniques and processes to facilitate a potentially better, more reliable system. Because consideration was given in the ESAS to both clean-sheet and modified USE designs, this paper will highlight the advantages and disadvantages of both approaches and provide a detailed discussion of trades/selections made that led to the final upper stage configuration.

SSME HPFTP/AT Turbine Blade Platform Featherseal Damper Design

NASA Technical Reports Server (NTRS)

Montgomery, S. K.

1999-01-01

During the Space Shuttle Main Engines (SSM) HPFtP/AT development program, engine hot fire testing resulted in turbine blade fatigue cracks. The cracks were noted after only a few tests and a several hundred seconds versus the design goal of 60 tests and >30,000 seconds. Subsequent investigation attributed the distress to excessive steady and dynamic loads. To address these excessive turbine blade loads, Pratt & Whitney Liquid Space Propulsion engineers designed and developed retrofitable turbine blade to blade platform featherseal dampers. Since incorporation of these dampers, along with other turbine blade system improvements, there has been no observed SSME HPFTP/AT turbine blade fatigue cracking. The high time HPFTP/AT blade now has accumulated 32 starts and 19,200 seconds hot fire test time. Figure #1 illustrates the HPFTP/AT turbine blade platform featherseal dampers. The approached selected was to improve the turbine blade structural capability while simultaneously reducing loads. To achieve this goal, the featherseal dampers were designed to seal the blade to blade platform gap and damp the dynamic motions. Sealing improves the steady stress margins by increasing turbine efficiency and improving turbine blade attachment thermal conditioning. Load reduction was achieved through damping. Thin Haynes 188 sheet metal was selected based on its material properties (hydrogen resistance, elongation, tensile strengths, etc.). The 36,000 rpm wheel speed of the rotor result in a normal load of 120#/blade. The featherseals then act as micro-slip dampers during actual SSME operation. After initial design and analysis (prior to full engine testing), the featherseal dampers were tested in P&W's spin rig facility in West Palm Beach, Florida. Both dynamic strain gages and turbine blade tip displacement measurements were utilized to quantify the featherseal damper effectiveness. Full speed (36,000 rpm), room temperature rig testing verified the elimination of fundamental mode (i.e, modes 1 & 2) resonant response. The reduction in turbine blade dynamic response is shown for a typical turbine blade. This paper discusses the design and verification of these dampers. The numerous benefits associated with this design concept warrants consideration in existing and future turbomachinery applications.

Automatic mathematical modeling for real time simulation system

NASA Technical Reports Server (NTRS)

Wang, Caroline; Purinton, Steve

1988-01-01

A methodology for automatic mathematical modeling and generating simulation models is described. The models will be verified by running in a test environment using standard profiles with the results compared against known results. The major objective is to create a user friendly environment for engineers to design, maintain, and verify their model and also automatically convert the mathematical model into conventional code for conventional computation. A demonstration program was designed for modeling the Space Shuttle Main Engine Simulation. It is written in LISP and MACSYMA and runs on a Symbolic 3670 Lisp Machine. The program provides a very friendly and well organized environment for engineers to build a knowledge base for base equations and general information. It contains an initial set of component process elements for the Space Shuttle Main Engine Simulation and a questionnaire that allows the engineer to answer a set of questions to specify a particular model. The system is then able to automatically generate the model and FORTRAN code. The future goal which is under construction is to download the FORTRAN code to VAX/VMS system for conventional computation. The SSME mathematical model will be verified in a test environment and the solution compared with the real data profile. The use of artificial intelligence techniques has shown that the process of the simulation modeling can be simplified.

External tank aerothermal design criteria verification

NASA Technical Reports Server (NTRS)

Praharaj, Sarat C.; Saladino, Anthony J.

1991-01-01

If a Space Shuttle Main Engine (SSME) fails during the initial 160 seconds of the Shuttle flight, a return-to-launch-site maneuver will be implemented. The period of concern for this task is the pitch-around maneuver when the vehicle is flying backward. The intent of this report is to identify and define the flowfield at the most critical locations from an environment perspective. The solution procedure used to predict the plume heating rates involves both computational analysis and engineering modeling.

Calculation of flow about posts and powerhead model

NASA Technical Reports Server (NTRS)

1988-01-01

A large number of computational fluid mechanics (CFD) problems were investigated. The primary studies include: the analysis of the turnaround duct/hot gas manifold/transfer tubes (fuel side) of the Space Shuttle Main Engine (SSME); the analysis of the LOX-T manifold (oxidizer side) of the SSME; the analysis of hydrogen accumulation in the Vandeburg flame trench; and modification of the Intel/VT241 systems to accommodate the EADS and PLOT 3D. Some of the analyses were exploratory in nature, using the CONTINUSYS code to provide preliminary information to enhance understanding of the problem, while in other the primary thrust was to acquire design information. In all cases the ability to predict information rapidly in these very complex analyses is seen to be an important demonstration of the power and utility of this mature predictive capability.

Vortex shedding experiment with flat and curved bluff plates in water

NASA Technical Reports Server (NTRS)

Reed, D.; Nesman, T.; Howard, P.

1988-01-01

Vortex shedding experiments were conducted in a water flow facility in order to simulate the strong discrete 4000-Hz vibration detected in the Space Shuttle Main Engine (SSME) which is thought to be associated with the SSME LOX inlet tee splitter vanes on the Main Injector. For the case of a flat vane with a blunt trailing edge excited by flow induced vortex shedding, lock-in with the first bending mode of the plate was observed. A curved vane displayed similar behavior, with the lock-in being a more discrete higher amplitude response. Aluminum vanes were employed to decouple the first vane bending mode from the vortex shedding mode. The application of an asymmetric 30-deg trailing edge bevel to both the flat and curved vanes was found to greatly reduce the strength of the shed vortices.

Turbine disk cavity aerodynamics and heat transfer

NASA Technical Reports Server (NTRS)

Johnson, B. V.; Daniels, W. A.

1992-01-01

Experiments were conducted to define the nature of the aerodynamics and heat transfer for the flow within the disk cavities and blade attachments of a large-scale model, simulating the Space Shuttle Main Engine (SSME) turbopump drive turbines. These experiments of the aerodynamic driving mechanisms explored the following: (1) flow between the main gas path and the disk cavities; (2) coolant flow injected into the disk cavities; (3) coolant density; (4) leakage flows through the seal between blades; and (5) the role that each of these various flows has in determining the adiabatic recovery temperature at all of the critical locations within the cavities. The model and the test apparatus provide close geometrical and aerodynamic simulation of all the two-stage cavity flow regions for the SSME High Pressure Fuel Turbopump and the ability to simulate the sources and sinks for each cavity flow.

Wear mechanisms found in angular contact ball bearings of the SSME's LOX turbopump

NASA Technical Reports Server (NTRS)

Chase, T. J.

1992-01-01

Extensive experimental investigations were carried out on used flight bearings of the Phase 2 high-pressure oxygen turbopump (HPOTP) of the Space Shuttle Main Engine (SSME) in order to determine the wear mechanisms, dominant wear modes, and their extent and causes. The report shows methodology, surface analysis techniques used, result, and discussion. The mode largely responsible for heavy bearing wear in LOX was identified as adhesive/shear peeling of the upper layers of bearing balls and rings. The mode relies on the mechanisms of scale formation, breakdown, and removal, all of which are greatly enhanced by the heavy oxidation environment of the HPOTP. Major causes of the high wear in bearings appear to be lubrication and cooling, both inadequate for the imposed conditions of operation. Numerous illustrations and evidence are given.

Heat transfer and pressure measurements for the SSME fuel turbine

NASA Technical Reports Server (NTRS)

Dunn, Michael G.; Kim, Jungho

1991-01-01

A measurement program is underway using the Rocketdyne two-stage Space Shuttle Main Engine (SSME) fuel turbine. The measurements use a very large shock tunnel to produce a short-duration source of heated and pressurized gas which is subsequently passed through the turbine. Within this environment, the turbine is operated at the design values of flow function, stage pressure ratio, stage temperature ratio, and corrected speed. The first stage vane row and the first stage blade row are instrumented in both the spanwise and chordwise directions with pressure transducers and heat flux gages. The specific measurements to be taken include time averaged surface pressure and heat flux distributions on the vane and blade, flow passage static pressure, flow passage total pressure and total temperature distributions, and phase resolved surface pressure and heat flux on the blade.

Investigation of breadboard temperature profiling system for SSME fuel preburner diagnostics

NASA Technical Reports Server (NTRS)

Shirley, J. A.

1986-01-01

The feasibility of measuring temperatures in the space shuttle main engine (SSME) fuel preburner using spontaneous Raman scattering from molecular hydrogen was studied. Laser radiation is transmitted to the preburner through a multimode optical fiber. Backscattered Raman-shifted light is collected and focused into a second fiber which connects to a remote-located spectrograph and a mutlichannel optical detector. Optics collimate and focus laser light from the transmitter fiber defining the probe volume. The high pressure, high temperature preburner environment was simulated by a heated pressure cell. Temperatures determined by the distribution of Q-branch co-vibrational transitions demonstrate precision and accuracy of 3%. It is indicated heat preburner temperatures can be determined with 5% accuracy with spatial resolution less than 1 cm and temporal resolution of 10 millisec at the nominal preburner operation conditions.

SSME - Materials and Methods for Addressing High-Pressure Hydrogen Embrittlement

NASA Technical Reports Server (NTRS)

Matejczk, Daniel; Russell, Dale; Frandsen, Jon; Swanson, Greg

2010-01-01

From the humid, corrosion-friendly atmosphere of KSC, to the extreme heat of ascent, to the cold vacuum of space, the Space Shuttle faced one hostile environment after another. One of those harsh environments the hydrogen environment existed within the shuttle itself. Liquid hydrogen was the fuel that powered the shuttle s complex, powerful, and reusable main engine. Hydrogen provided the high specific impulse the bang per pound of fuel needed to perform the shuttle s heavy lifting duties. Hydrogen, however, was also a potential threat to the very metal of the propulsion system that used it. The diffusion of hydrogen atoms into a metal can make it more brittle and prone to cracking a process called hydrogen embrittlement. This effect can reduce the toughness of carefully selected and prepared materials. A concern that exposure to hydrogen might encourage crack growth was present from the beginning of the Space Shuttle Program, but the rationale for using hydrogen was compelling. This paper outlines the material characterization, anomaly resolution, and path to understanding of hydrogen embrittlement on superalloys through the course of the SSME program. Specific examples of nickel alloy turbine housings and single crystal turbine blades are addressed. The evolution of fracture mechanics analytical methods is also addressed.

Probabilistic evaluation of uncertainties and risks in aerospace components

NASA Technical Reports Server (NTRS)

Shah, A. R.; Shiao, M. C.; Nagpal, V. K.; Chamis, C. C.

1992-01-01

This paper summarizes a methodology developed at NASA Lewis Research Center which computationally simulates the structural, material, and load uncertainties associated with Space Shuttle Main Engine (SSME) components. The methodology was applied to evaluate the scatter in static, buckling, dynamic, fatigue, and damage behavior of the SSME turbo pump blade. Also calculated are the probability densities of typical critical blade responses, such as effective stress, natural frequency, damage initiation, most probable damage path, etc. Risk assessments were performed for different failure modes, and the effect of material degradation on the fatigue and damage behaviors of a blade were calculated using a multi-factor interaction equation. Failure probabilities for different fatigue cycles were computed and the uncertainties associated with damage initiation and damage propagation due to different load cycle were quantified. Evaluations on the effects of mistuned blades on a rotor were made; uncertainties in the excitation frequency were found to significantly amplify the blade responses of a mistuned rotor. The effects of the number of blades on a rotor were studied. The autocorrelation function of displacements and the probability density function of the first passage time for deterministic and random barriers for structures subjected to random processes also were computed. A brief discussion was included on the future direction of probabilistic structural analysis.

Space Shuttle main engine powerhead structural modeling, stress and fatigue life analysis. Volume 2: Dynamics of blades and nozzles SSME HPFTP and HPOTP

NASA Technical Reports Server (NTRS)

Hammett, J. C.; Hayes, C. H.; Price, J. M.; Robinson, J. K.; Teal, G. A.; Thomson, J. M.; Tilley, D. M.; Welch, C. T.

1983-01-01

Normal modes of the blades and nozzles of the HPFTP and HPOTP are defined and potential driving forces for the blades are identified. The computer models used in blade analyses are described, with results. Similar information is given for the nozzles.

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

NASA Technical Reports Server (NTRS)

Kim, Jonnathan H.

1995-01-01

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).

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.

Prediction of the Thrust Performance and the Flowfield of Liquid Rocket Engines

NASA Technical Reports Server (NTRS)

Wang, T.-S.

1990-01-01

In an effort to improve the current solutions in the design and analysis of liquid propulsive engines, a computational fluid dynamics (CFD) model capable of calculating the reacting flows from the combustion chamber, through the nozzle to the external plume, was developed. The Space Shuttle Main Engine (SSME) fired at sea level, was investigated as a sample case. The CFD model, FDNS, is a pressure based, non-staggered grid, viscous/inviscid, ideal gas/real gas, reactive code. An adaptive upwinding differencing scheme is employed for the spatial discretization. The upwind scheme is based on fourth order central differencing with fourth order damping for smooth regions, and second order central differencing with second order damping for shock capturing. It is equipped with a CHMQGM equilibrium chemistry algorithm and a PARASOL finite rate chemistry algorithm using the point implicit method. The computed flow results and performance compared well with those of other standard codes and engine hot fire test data. In addition, the transient nozzle flowfield calculation was also performed to demonstrate the ability of FDNS in capturing the flow separation during the startup process.

Development of new materials for turbopump bearings

NASA Technical Reports Server (NTRS)

Maurer, R. E.; Pallini, R. A.

1985-01-01

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life was experienced. The objective is to identify bearing materials and/or materials processing techniques offering signficant potential for extending HPOTP bearing performance life. Interactive thermomechanical analysis of the HPOTP bearing-shaft system was performed with the SHABERTH computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures and circumferential stress in the inner rings were quantified as functions of radial load, thrust load and ball-race contact friction. Criteria established from the output of this analysis are being used for material candidate selection.

Time-frequency representation of a highly nonstationary signal via the modified Wigner distribution

NASA Technical Reports Server (NTRS)

Zoladz, T. F.; Jones, J. H.; Jong, J.

1992-01-01

A new signal analysis technique called the modified Wigner distribution (MWD) is presented. The new signal processing tool has been very successful in determining time frequency representations of highly non-stationary multicomponent signals in both simulations and trials involving actual Space Shuttle Main Engine (SSME) high frequency data. The MWD departs from the classic Wigner distribution (WD) in that it effectively eliminates the cross coupling among positive frequency components in a multiple component signal. This attribute of the MWD, which prevents the generation of 'phantom' spectral peaks, will undoubtedly increase the utility of the WD for real world signal analysis applications which more often than not involve multicomponent signals.

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 model of the High Pressure Oxidizer Turbopump (HPOTP) shaft seal system on the Space Shuttle Main Engine (SSME) is described. The model predicts the fluid properties and flow rates throughout this system for a number of conditions simulating failed seals. The results agree well with qualitative expectations and redline values but cannot be verified with actual data due to the lack thereof. The results indicate that each failure mode results in a unique distribution of properties throughout the seal system and can therefore be individually identified given the proper instrumentation. Furthermore, the detection process can be built on the principle of qualitative reasoning without the use of exact fluid property values. A simplified implementation of the model which does not include the slinger/labyrinth seal combination has been developed and will be useful for inclusion in a real-time diagnostic system.

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

NASA Technical Reports Server (NTRS)

Jones, C. S.; Gangl, K. J.

1986-01-01

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

An SSME High Pressure Oxidizer Turbopump diagnostic system using G2 real-time expert system

NASA Technical Reports Server (NTRS)

Guo, Ten-Huei

1991-01-01

An expert system which diagnoses various seal leakage faults in the High Pressure Oxidizer Turbopump of the SSME was developed using G2 real-time expert system. Three major functions of the software were implemented: model-based data generation, real-time expert system reasoning, and real-time input/output communication. This system is proposed as one module of a complete diagnostic system for the SSME. Diagnosis of a fault is defined as the determination of its type, severity, and likelihood. Since fault diagnosis is often accomplished through the use of heuristic human knowledge, an expert system based approach has been adopted as a paradigm to develop this diagnostic system. To implement this approach, a software shell which can be easily programmed to emulate the human decision process, the G2 Real-Time Expert System, was selected. Lessons learned from this implementation are discussed.

Endeavour Grand Opening Ceremony

NASA Image and Video Library

2012-10-30

A space shuttle main engine (SSME) is on display near the space shuttle Endeavour at the California Science center's Samuel Oschin Space Shuttle Endeavour Display Pavilion, Tuesday, Oct. 30, 2012, in Los Angeles. Endeavour, built as a replacement for space shuttle Challenger, completed 25 missions, spent 299 days in orbit, and orbited Earth 4,671 times while traveling 122,883,151 miles. Photo Credit: (NASA/Bill Ingalls)

Milestone report TCTP application to the SSME hydrogen system analysis

NASA Technical Reports Server (NTRS)

Richards, J. S.

1975-01-01

The Transient Cryogen Transfer Computer Program (TCTP) developed and verified for LOX systems by analyses of Skylab S-1B stage loading data from John F. Kennedy Space Center launches was extended to include hydrogen as the working fluid. The feasibility of incorporating TCTP into the space shuttle main engine dynamic model was studied. The program applications are documented.

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.

Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 6: Primary nozzle diffuser analysis

NASA Technical Reports Server (NTRS)

Foley, Michael J.

1989-01-01

The primary nozzle diffuser routes fuel from the main fuel valve on the Space Shuttle Main Engine (SSME) to the nozzle coolant inlet mainfold, main combustion chamber coolant inlet mainfold, chamber coolant valve, and the augmented spark igniters. The diffuser also includes the fuel system purge check valve connection. A static stress analysis was performed on the diffuser because no detailed analysis was done on this part in the past. Structural concerns were in the area of the welds because approximately 10 percent are in areas inaccessible by X-ray testing devices. Flow dynamics and thermodynamics were not included in the analysis load case. Constant internal pressure at maximum SSME power was used instead. A three-dimensional, finite element method was generated using ANSYS version 4.3A on the Lockheed VAX 11/785 computer to perform the stress computations. IDEAS Supertab on a Sun 3/60 computer was used to create the finite element model. Rocketdyne drawing number RS009156 was used for the model interpretation. The flight diffuser is denoted as -101. A description of the model, boundary conditions/load case, material properties, structural analysis/results, and a summary are included for documentation.

Fault-Detection Tool Has Companies 'Mining' Own Business

NASA Technical Reports Server (NTRS)

2005-01-01

A successful launching of NASA's Space Shuttle hinges heavily on the three Space Shuttle Main Engines (SSME) that power the orbiter. These critical components must be monitored in real time, with sensors, and compared against expected behaviors that could scrub a launch or, even worse, cause in- flight hazards. Since 1981, SSME faults have caused 23 scrubbed launches and 29 percent of total Space Shuttle downtime, according to a compilation of analysis reports. The most serious cases typically occur in the last few seconds before ignition; a launch scrub that late in the countdown usually means a period of investigation of a month or more. For example, during the launch attempt of STS-41D in 1984, an anomaly was detected in the number three engine, causing the mission to be scrubbed at T-4 seconds. This not only affected STS-41D, but forced the cancellation of another mission and caused a 2-month flight delay. In 2002, NASA s Kennedy Space Center, the Florida Institute of Technology, and Interface & Control Systems, Inc., worked together to attack this problem by creating a system that could automate the detection of mechanical failures in the SSMEs fuel control valves.

Viscoplastic analysis of an experimental cylindrical thrust chamber liner

NASA Technical Reports Server (NTRS)

Arya, Vinod K.; Arnold, Steven M.

1991-01-01

A viscoplastic stress-strain analysis of an experimental cylindrical thrust chamber is presented. A viscoelastic constitutive model incorporating a single internal state variable that represents kinematic hardening was employed to investigate whether such a viscoplastic model could predict the experimentally observed behavior of the thrust chamber. Two types of loading cycles were considered: a short cycle of 3.5 sec. duration that corresponded to the experiments, and an extended loading cycle of 485.1 sec. duration that is typical of the Space Shuttle Main Engine (SSME) operating cycle. The analysis qualitatively replicated the deformation behavior of the component as observed in experiments designed to simulate SSME operating conditions. The analysis also showed that the mode and location in the component may depend on the loading cycle. The results indicate that using viscoplastic models for structural analysis can lead to a more realistic life assessment of thrust chambers.

Overview of aerothermodynamic loads definition study

NASA Technical Reports Server (NTRS)

Gaugler, Raymond E.

1989-01-01

Over the years, NASA has been conducting the Advanced Earth-to-Orbit (AETO) Propulsion Technology Program to provide the knowledge, understanding, and design methodology that will allow the development of advanced Earth-to-orbit propulsion systems with high performance, extended service life, automated operations, and diagnostics for in-flight health monitoring. The objective of the Aerothermodynamic Loads Definition Study is to develop methods to more accurately predict the operating environment in AETO propulsion systems, such as the Space Shuttle Main Engine (SSME) powerhead. The approach taken consists of 2 parts: to modify, apply, and disseminate existing computational fluid dynamics tools in response to current needs and to develop new technology that will enable more accurate computation of the time averaged and unsteady aerothermodynamic loads in the SSME powerhead. The software tools are detailed. Significant progress was made in the area of turbomachinery, where there is an overlap between the AETO efforts and research in the aeronautical gas turbine field.

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

The purpose of Modification No. 5 of this contract is to expand the scope of work (Task C) of this research study effort to develop pressure instrumentation for the SSME. The objective of this contract (Task C) is to direct Honeywell's Solid State Electronics Division's (SSED) extensive experience and expertise in solid state sensor technology to develop prototype pressure transducers which are targeted to meet the SSME performance design goals and to fabricate, test and deliver a total of 10 prototype units. SSED's basic approach is to effectively utilize the many advantages of silicon piezoresistive strain sensing technology to achieve the objectives of advanced state-of-the-art pressure sensors in terms of reliability, accuracy and ease of manufacture. More specifically, integration of multiple functions on a single chip is the key attribute of this technology which will be exploited during this research study.

Replacement bearing for Rocketdyne SSME HPOTPs using alternate self-lubricating retainer materials

NASA Technical Reports Server (NTRS)

Gleeson, J.; Dufrane, K.; Kannel, J.

1992-01-01

Research was conducted to develop replacement bearings for the Rocketdyne Space Shuttle main engine (SSME) high pressure oxidizer turbopumps (HPOTPs). The replacement bearings consisted of standard balls and races with a special Battelle Self-Lubricating Insert Configuration (BASIC) retainer. The BASIC retainer consists of a phosphor bronze housing with inserts consisting of a polytetrafluoretheylene (PTFE) and bronze compound. The PTFE contacts the balls and the land guiding surface on the outer race. A PTFE transfer film is formed on balls and races, which lubricates the critical interfaces. The BASIC retainer is a one-to-one replacement for the current Armalon retainer, but has superior lubricating properties and is stronger over the broad temperature range anticipated for the HPOTP bearings. As a part of the project 40 sets of balls and races (two sizes) and 52 BASIC retainers were shipped to NASA/MSFC.

SSME structural dynamic model development

NASA Technical Reports Server (NTRS)

Foley, Michael J.

1989-01-01

The high pressure fuel turbopump (HPFTP) is a major component of the Space Shuttle Main Engine (SSME) powerhead. The device is a three stage centrifugal pump that is directly driven by a two stage hot gas turbine. The purpose of the pump is to deliver fuel (liquid hydrogen) from the low pressure fuel turbopump (LPFTP) through the main fuel valve (MFV) to the thrust chamber coolant circuits. In doing so, the pump pressurizes the fuel from an inlet pressure of approximately 178 psi to a discharge pressure of over 6000 psi. At full power level (FPL), the pump rotates at a speed of over 37,000 rpm while generating approximately 77,000 horsepower. Obviously, a pump failure at these speeds and power levels could jeopardize the mission. Results are summarized for work in which the solutions obtained from analytical models of the fuel turbopump impellers are compared with the results obtained from dynamic tests.

Computational analysis of the SSME fuel preburner flow

NASA Technical Reports Server (NTRS)

Wang, T. S.; Farmer, R. C.

1986-01-01

A computational fluid dynamics model which simulates the steady state operation of the SSME fuel preburner is developed. Specifically, the model will be used to quantify the flow factors which cause local hot spots in the fuel preburner in order to recommend experiments whereby the control of undesirable flow features can be demonstrated. The results of a two year effort to model the preburner are presented. In this effort, investigating the fuel preburner flowfield, the appropriate transport equations were numerically solved for both an axisymmetric and a three-dimensional configuration. Continuum's VAST (Variational Solution of the Transport equations) code, in conjunction with the CM-1000 Engineering Analysis Workstation and the NASA/Ames CYBER 205, was used to perform the required calculations. It is concluded that the preburner operational anomalies are not due to steady state phenomena and must, therefore, be related to transient operational procedures.

Turbomachinery aeroelasticity at NASA Lewis Research Center

NASA Technical Reports Server (NTRS)

Kaza, Krishna Rao V.

1989-01-01

The turbomachinery aeroelastic effort is focused on unstalled and stalled flutter, forced response, and whirl flutter of both single rotation and counter rotation propfans. It also includes forced response of the Space Shuttle Main Engine (SSME) turbopump blades. Because of certain unique features of propfans and the SSME turbopump blades, it is not possible to directly use the existing aeroelastic technology of conventional propellers, turbofans or helicopters. Therefore, reliable aeroelastic stability and response analysis methods for these propulsion systems must be developed. The development of these methods for propfans requires specific basic technology disciplines, such as 2-D and 3-D steady and unsteady aerodynamic theories in subsonic, transonic and supersonic flow regimes; modeling of composite blades; geometric nonlinear effects; and passive and active control of flutter and response. These methods are incorporated in a computer program, ASTROP. The program has flexibility such that new and future models in basic disciplines can be easily implemented.

Bearings working group

NASA Technical Reports Server (NTRS)

1985-01-01

The service life of the Space Shuttle Main Engine (SSME) turbomachinery bearings was a predominant factor in engine durability and maintenance problems. Recent data has indicated that bearing life is about one order of magnitude lower than the goal of seven and one-half hours particularly those in the High Pressure Oxidizer Turbopump (HPOTP). Bearing technology, primarily cryogenic turbomachinery bearing technology, is expanded by exploring the life and performance effects of design changes; design concept changes; materials changes; manufacturing technique changes; and lubrication system changes. Each variation is assessed against the current bearing design in full scale cryogenic tests.

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.

A Framework for Assessing the Reusability of Hardware (Reusable Rocket Engines)

NASA Technical Reports Server (NTRS)

Childress-Thompson, Rhonda; Farrington, Philip; Thomas, Dale

2016-01-01

Within the space flight community, reusability has taken center stage as the new buzzword. In order for reusable hardware to be competitive with its expendable counterpart, two major elements must be closely scrutinized. First, recovery and refurbishment costs must be lower than the development and acquisition costs. Additionally, the reliability for reused hardware must remain the same (or nearly the same) as "first use" hardware. Therefore, it is imperative that a systematic approach be established to enhance the development of reusable systems. However, before the decision can be made on whether it is more beneficial to reuse hardware or to replace it, the parameters that are needed to deem hardware worthy of reuse must be identified. For reusable hardware to be successful, the factors that must be considered are reliability (integrity, life, number of uses), operability (maintenance, accessibility), and cost (procurement, retrieval, refurbishment). These three factors are essential to the successful implementation of reusability while enabling the ability to meet performance goals. Past and present strategies and attempts at reuse within the space industry will be examined to identify important attributes of reusability that can be used to evaluate hardware when contemplating reusable versus expendable options. This paper will examine why reuse must be stated as an initial requirement rather than included as an afterthought in the final design. Late in the process, changes in the overall objective/purpose of components typically have adverse effects that potentially negate the benefits. A methodology for assessing the viability of reusing hardware will be presented by using the Space Shuttle Main Engine (SSME) to validate the approach. Because reliability, operability, and costs are key drivers in making this critical decision, they will be used to assess requirements for reuse as applied to components of the SSME.

Conversion-Integration of MSFC Nonlinear Signal Diagnostic Analysis Algorithms for Realtime Execution of MSFC's MPP Prototype System

NASA Technical Reports Server (NTRS)

Jong, Jen-Yi

1996-01-01

NASA's advanced propulsion system Small Scale Magnetic Disturbances/Advanced Technology Development (SSME/ATD) has been undergoing extensive flight certification and developmental testing, which involves large numbers of health monitoring measurements. To enhance engine safety and reliability, detailed analysis and evaluation of the measurement signals are mandatory to assess its dynamic characteristics and operational condition. Efficient and reliable signal detection techniques will reduce the risk of catastrophic system failures and expedite the evaluation of both flight and ground test data, and thereby reduce launch turn-around time. During the development of SSME, ASRI participated in the research and development of several advanced non- linear signal diagnostic methods for health monitoring and failure prediction in turbomachinery components. However, due to the intensive computational requirement associated with such advanced analysis tasks, current SSME dynamic data analysis and diagnostic evaluation is performed off-line following flight or ground test with a typical diagnostic turnaround time of one to two days. The objective of MSFC's MPP Prototype System is to eliminate such 'diagnostic lag time' by achieving signal processing and analysis in real-time. Such an on-line diagnostic system can provide sufficient lead time to initiate corrective action and also to enable efficient scheduling of inspection, maintenance and repair activities. The major objective of this project was to convert and implement a number of advanced nonlinear diagnostic DSP algorithms in a format consistent with that required for integration into the Vanderbilt Multigraph Architecture (MGA) Model Based Programming environment. This effort will allow the real-time execution of these algorithms using the MSFC MPP Prototype System. ASRI has completed the software conversion and integration of a sequence of nonlinear signal analysis techniques specified in the SOW for real-time execution on MSFC's MPP Prototype. This report documents and summarizes the results of the contract tasks; provides the complete computer source code; including all FORTRAN/C Utilities; and all other utilities/supporting software libraries that are required for operation.

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

The advantages of silicon piezoresistive strain sensing technology are being used to achieve the objectives of state of the art pressure sensors for SSME applications. The integration of multiple functions on a single chip is the key attribute being exploited. Progress is reported in transducer packaging and materials; silicon resistor characterization at cryogenic temperatures; chip mounting; and frequency response optimization.

SSME Alternate Turbopump Development Program: Design verification specification for high-pressure fuel turbopump

NASA Technical Reports Server (NTRS)

1989-01-01

The design and verification requirements are defined which are appropriate to hardware at the detail, subassembly, component, and engine levels and to correlate these requirements to the development demonstrations which provides verification that design objectives are achieved. The high pressure fuel turbopump requirements verification matrix provides correlation between design requirements and the tests required to verify that the requirement have been met.

STS-80 Space Shuttle Mission Report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1997-01-01

The STS-80 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the eightieth flight of the Space Shuttle Program, the fifty-fifth flight since the return-to-flight, and the twenty-first flight of the Orbiter Columbia (OV-102).

Space shuttle propulsion systems

NASA Technical Reports Server (NTRS)

Bardos, Russell

1991-01-01

This is a presentation of view graphs. The design parameters are given for the redesigned solid rocket motor (RSRM), the Advanced Solid Rocket Motor (ASRM), Space Shuttle Main Engine (SSME), Solid Rocket Booster (SRB) separation motor, Orbit Maneuvering System (OMS), and the Reaction Control System (RCS) primary and Vernier thrusters. Space shuttle propulsion issues are outlined along with ASA program definition, ASA program selection methodology, its priorities, candidates, and categories.

The Role of Structural Dynamics and Testing in the Shuttle Flowliner Crack Investigation

NASA Technical Reports Server (NTRS)

Frady, Gregory P.

2005-01-01

During a normal inspection of the main propulsion system at Kennedy Space Center, small cracks were noticed near a slotted region of a gimbal joint flowliner located just upstream from one of the Space Shuttle Main Engines (SSME). These small cracks sparked an investigation of the entire Space Shuttle fleet main propulsion feedlines. The investigation was initiated to determine the cause of the small cracks and a repair method that would be needed to return the Shuttle fleet back to operation safely. The cracks were found to be initiated by structural resonance caused by flow fluctuations from the SSME low pressure fuel turbopump interacting with the flowliner. The pump induced backward traveling wakes that excited the liner and duct acoustics which also caused the liner to vibrate in complex mode shapes. The investigation involved an extensive effort by a team of engineers from the NASA civil servant and contractor workforce with the goal to characterize the root cause of the cracking behavior of the fuel side gimbal joint flowliners. In addition to working to identify the root cause, a parallel path was taken to characterize the material properties and fatigue capabilities of the liner material such that the life of the liners could be ascertained. As the characterization of the material and the most probable cause matured, the combination of the two with pump speed restrictions provided a means to return the Shuttle to flight in a safe manner. This paper traces the flowliner investigation results with respect to the structural dynamics analysis, component level testing and hot-fire flow testing on a static testbed. The paper will address the unique aspects of a very complex problem involving backflow from a high performance pump that has never been characterized nor understood to such detail. In addition, the paper will briefly address the flow phenomena that excited the liners, the unique structural dynamic modal characteristics and the variability of SSME operation which has ultimately ensured the safe and reliable operation of the shuttle main engines for each flight.

Probabilistic SSME blades structural response under random pulse loading

NASA Technical Reports Server (NTRS)

Shiao, Michael; Rubinstein, Robert; Nagpal, Vinod K.

1987-01-01

The purpose is to develop models of random impacts on a Space Shuttle Main Engine (SSME) turbopump blade and to predict the probabilistic structural response of the blade to these impacts. The random loading is caused by the impact of debris. The probabilistic structural response is characterized by distribution functions for stress and displacements as functions of the loading parameters which determine the random pulse model. These parameters include pulse arrival, amplitude, and location. The analysis can be extended to predict level crossing rates. This requires knowledge of the joint distribution of the response and its derivative. The model of random impacts chosen allows the pulse arrivals, pulse amplitudes, and pulse locations to be random. Specifically, the pulse arrivals are assumed to be governed by a Poisson process, which is characterized by a mean arrival rate. The pulse intensity is modelled as a normally distributed random variable with a zero mean chosen independently at each arrival. The standard deviation of the distribution is a measure of pulse intensity. Several different models were used for the pulse locations. For example, three points near the blade tip were chosen at which pulses were allowed to arrive with equal probability. Again, the locations were chosen independently at each arrival. The structural response was analyzed both by direct Monte Carlo simulation and by a semi-analytical method.

A Framework for Assessing the Reusability of Hardware (Reusable Rocket Engines)

NASA Technical Reports Server (NTRS)

Childress-Thompson, Rhonda; Thomas, Dale; Farrington, Philip

2016-01-01

Within the past few years, there has been a renewed interest in reusability as it applies to space flight hardware. Commercial companies such as Space Exploration Technologies Corporation (SpaceX), Blue Origin, and United Launch Alliance (ULA) are pursuing reusable hardware. Even foreign companies are pursuing this option. The Indian Space Research Organization (ISRO) launched a reusable space plane technology demonstrator and Airbus Defense and Space is planning to recover the main engines and avionics from its Advanced Expendable Launcher with Innovative engine Economy [1] [2]. To date, the Space Shuttle remains as the only Reusable Launch (RLV) to have flown repeated missions and the Space Shutte Main Engine (SSME) is the only demonstrated reusable engine. Whether the hardware being considered for reuse is a launch vehicle (fully reusable), a first stage (partially reusable), or a booster engine (single component), the overall governing process is the same; it must be recovered and recertified for flight. Therefore, there is a need to identify the key factors in determining the reusability of flight hardware. This paper begins with defining reusability to set the context, addresses the significance of reuse, and discusses areas that limit successful implementation. Finally, this research identifies the factors that should be considered when incorporating reuse.

A Three-Dimensional Parallel Time-Accurate Turbopump Simulation Procedure Using Overset Grid System

NASA Technical Reports Server (NTRS)

Kiris, Cetin; Chan, William; Kwak, Dochan

2002-01-01

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and nonuniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability are presented along with the performance of parallel versions of the code.

Time-Dependent Simulations of Turbopump Flows

NASA Technical Reports Server (NTRS)

Kris, Cetin C.; Kwak, Dochan

2001-01-01

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort will provide developers with information such as transient flow phenomena at start up, impact of non-uniform inflows, system vibration and impact on the structure. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Time-accuracy of the scheme has been evaluated with simple test cases. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Probabilistic structural analysis methods of hot engine structures

NASA Technical Reports Server (NTRS)

Chamis, C. C.; Hopkins, D. A.

1989-01-01

Development of probabilistic structural analysis methods for hot engine structures at Lewis Research Center is presented. Three elements of the research program are: (1) composite load spectra methodology; (2) probabilistic structural analysis methodology; and (3) probabilistic structural analysis application. Recent progress includes: (1) quantification of the effects of uncertainties for several variables on high pressure fuel turbopump (HPFT) turbine blade temperature, pressure, and torque of the space shuttle main engine (SSME); (2) the evaluation of the cumulative distribution function for various structural response variables based on assumed uncertainties in primitive structural variables; and (3) evaluation of the failure probability. Collectively, the results demonstrate that the structural durability of hot engine structural components can be effectively evaluated in a formal probabilistic/reliability framework.

On-board Optical Spectrometry for Detection of Mixture Ratio and Eroded Materials in Rocket Engine Exhaust Plume

NASA Technical Reports Server (NTRS)

Barkhoudarian, Sarkis; Kittinger, Scott

2006-01-01

Optical spectrometry can provide means to characterize rocket engine exhaust plume impurities due to eroded materials, as well as combustion mixture ratio without any interference with plume. Fiberoptic probes and cables were designed, fabricated and installed on Space Shuttle Main Engines (SSME), allowing monitoring of the plume spectra in real time with a Commercial of the Shelf (COTS) fiberoptic spectrometer, located in a test-stand control room. The probes and the cables survived the harsh engine environments for numerous hot-fire tests. When the plume was seeded with a nickel alloy powder, the spectrometer was able to successfully detect all the metallic and OH radical spectra from 300 to 800 nanometers.

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.

Probabilistic structural analysis methods for space propulsion system components

NASA Technical Reports Server (NTRS)

Chamis, C. C.

1986-01-01

The development of a three-dimensional inelastic analysis methodology for the Space Shuttle main engine (SSME) structural components is described. The methodology is composed of: (1) composite load spectra, (2) probabilistic structural analysis methods, (3) the probabilistic finite element theory, and (4) probabilistic structural analysis. The methodology has led to significant technical progress in several important aspects of probabilistic structural analysis. The program and accomplishments to date are summarized.

KSC-00pp1416

NASA Image and Video Library

2000-09-08

KENNEDY SPACE CENTER, FLA. -- This view of the shock wave condensation collars backlit by the sun occurred during the launch of Atlantis on STS-106 and was captured on an engineering 35mm motion picture film. One frame was digitized to make this still image. Although the primary effect is created by the Orbiter forward fuselage, secondary effects can be seen on the SRB forward skirt, Orbiter vertical stabilizer and wing trailing edges (behind SSME's).

KSC00pp1416

NASA Image and Video Library

2000-09-08

KENNEDY SPACE CENTER, FLA. -- This view of the shock wave condensation collars backlit by the sun occurred during the launch of Atlantis on STS-106 and was captured on an engineering 35mm motion picture film. One frame was digitized to make this still image. Although the primary effect is created by the Orbiter forward fuselage, secondary effects can be seen on the SRB forward skirt, Orbiter vertical stabilizer and wing trailing edges (behind SSME's).

Simulation of multistage turbine flows

NASA Technical Reports Server (NTRS)

Adamczyk, John J.; Mulac, Richard A.

1987-01-01

A flow model has been developed for analyzing multistage turbomachinery flows. This model, referred to as the average passage flow model, describes the time-averaged flow field with a typical passage of a blade row embedded within a multistage configuration. Computer resource requirements, supporting empirical modeling, formulation code development, and multitasking and storage are discussed. Illustrations from simulations of the space shuttle main engine (SSME) fuel turbine performed to date are given.

Compendium of fracture mechanics problems

NASA Technical Reports Server (NTRS)

Stallworth, R.; Wilson, C.; Meyers, C.

1990-01-01

Fracture mechanics analysis results are presented from the following structures/components analyzed at Marshall Space Flight Center (MSFC) between 1982 and 1989: space shuttle main engine (SSME), Hubble Space Telescope (HST), external tank attach ring, B-1 stand LOX inner tank, and solid rocket booster (SRB). Results from the SSME high pressure fuel turbopump (HPFTP) second stage blade parametric analysis determine a critical flaw size for a wide variety of stress intensity values. The engine 0212 failure analysis was a time dependent fracture life assessment. Results indicated that the disk ruptured due to an overspeed condition. Results also indicated that very small flaws in the curvic coupling area could propagate and lead to failure under normal operating conditions. It was strongly recommended that a nondestructive evaluation inspection schedule be implemented. The main ring of the HST, scheduled to launch in 1990, was analyzed by safe-life and fail-safe analyses. First safe-life inspection criteria curves for the ring inner and outer skins and the fore and aft channels were derived. Afterwards the skins and channels were determined to be fail-safe by analysis. A conservative safe-life analysis was done on the 270 redesign external tank attach ring. Results from the analysis were used to determine the nondestructive evaluation technique required.

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.

Around Marshall

NASA Image and Video Library

2002-10-01

This is a ground level view of Test Stand 500 at the east test area of the Marshall Space Flight Center. Originally constructed in 1966, Test Stand 500 is a multipurpose, dual-position test facility. The stand was utilized to test liquid hydrogen/liquid oxygen turbopumps and combustion devices for the J-2 engine. One test position has a high superstructure with lines and tankage for testing liquid hydrogen and liquid oxygen turbopumps while the other position is adaptable to pressure-fed test programs such as turbo machinery bearings or seals. The facility was modified in 1980 to support Space Shuttle main engine (SSME) bearing testing.

An approximate methods approach to probabilistic structural analysis

NASA Technical Reports Server (NTRS)

Mcclung, R. C.; Millwater, H. R.; Wu, Y.-T.; Thacker, B. H.; Burnside, O. H.

1989-01-01

A probabilistic structural analysis method (PSAM) is described which makes an approximate calculation of the structural response of a system, including the associated probabilistic distributions, with minimal computation time and cost, based on a simplified representation of the geometry, loads, and material. The method employs the fast probability integration (FPI) algorithm of Wu and Wirsching. Typical solution strategies are illustrated by formulations for a representative critical component chosen from the Space Shuttle Main Engine (SSME) as part of a major NASA-sponsored program on PSAM. Typical results are presented to demonstrate the role of the methodology in engineering design and analysis.

Cryogenic propellant management: Integration of design, performance and operational requirements

NASA Technical Reports Server (NTRS)

Worlund, A. L.; Jamieson, J. R., Jr.; Cole, T. W.; Lak, T. I.

1985-01-01

The integration of the design features of the Shuttle elements into a cryogenic propellant management system is described. The implementation and verification of the design/operational changes resulting from design deficiencies and/or element incompatibilities encountered subsequent to the critical design reviews are emphasized. Major topics include: subsystem designs to provide liquid oxygen (LO2) tank pressure stabilization, LO2 facility vent for ice prevention, liquid hydrogen (LH2) feedline high point bleed, pogo suppression on the Space Shuttle Main Engine (SSME), LO2 low level cutoff, Orbiter/engine propellant dump, and LO2 main feedline helium injection for geyser prevention.

KSC-2011-7698

NASA Image and Video Library

2011-11-09

CAPE CANAVERAL, Fla. – At the Turn Basin in the Launch Complex 39 area of NASA’s Kennedy Space Center in Florida, parts of the Hyster forklift, a specially designed engine installer used in conjunction with the space shuttle main engines (SSME), are stowed away inside the Pegasus barge, ready for transport for delivery to Stennis Space Center near Bay St. Louis, Miss. Since being delivered to NASA in 1999, Pegasus sailed 41 times and transported 31 shuttle external fuel tanks from Michoud Assembly Facility near New Orleans to Kennedy. The barge will leave Kennedy, perhaps for the final time. Both the barge and shuttle equipment will remain in storage until their specific future uses are determined. The SSMEs themselves will be transported to Stennis separately for use with the agency’s new heavy-lift rocket, the Space Launch System. The work is part of the Space Shuttle Program’s transition and retirement processing. For more information about Shuttle Transition and Retirement, visit http://www.nasa.gov/mission_pages/transition/home/index.html. Photo credit: NASA/Cory Huston

KSC-2011-7700

NASA Image and Video Library

2011-11-09

CAPE CANAVERAL, Fla. – At the Turn Basin in the Launch Complex 39 area of NASA’s Kennedy Space Center in Florida, parts of the Hyster forklift, a specially designed engine installer used in conjunction with the space shuttle main engines (SSME), are stowed away inside the Pegasus barge, ready for transport for delivery to Stennis Space Center near Bay St. Louis, Miss. Since being delivered to NASA in 1999, Pegasus sailed 41 times and transported 31 shuttle external fuel tanks from Michoud Assembly Facility near New Orleans to Kennedy. The barge will leave Kennedy, perhaps for the final time. Both the barge and shuttle equipment will remain in storage until their specific future uses are determined. The SSMEs themselves will be transported to Stennis separately for use with the agency’s new heavy-lift rocket, the Space Launch System. The work is part of the Space Shuttle Program’s transition and retirement processing. For more information about Shuttle Transition and Retirement, visit http://www.nasa.gov/mission_pages/transition/home/index.html. Photo credit: NASA/Cory Huston

Evaluation of space shuttle main engine fluid dynamic frequency response characteristics

NASA Technical Reports Server (NTRS)

Gardner, T. G.

1980-01-01

In order to determine the POGO stability characteristics of the space shuttle main engine liquid oxygen (LOX) system, the fluid dynamic frequency response functions between elements in the SSME LOX system was evaluated, both analytically and experimentally. For the experimental data evaluation, a software package was written for the Hewlett-Packard 5451C Fourier analyzer. The POGO analysis software is documented and consists of five separate segments. Each segment is stored on the 5451C disc as an individual program and performs its own unique function. Two separate data reduction methods, a signal calibration, coherence or pulser signal based frequency response function blanking, and automatic plotting features are included in the program. The 5451C allows variable parameter transfer from program to program. This feature is used to advantage and requires only minimal user interface during the data reduction process. Experimental results are included and compared with the analytical predictions in order to adjust the general model and arrive at a realistic simulation of the POGO characteristics.

Signal Detection Techniques for Diagnostic Monitoring of Space Shuttle Main Engine Turbomachinery

NASA Technical Reports Server (NTRS)

Coffin, Thomas; Jong, Jen-Yi

1986-01-01

An investigation to develop, implement, and evaluate signal analysis techniques for the detection and classification of incipient mechanical failures in turbomachinery is reviewed. A brief description of the Space Shuttle Main Engine (SSME) test/measurement program is presented. Signal analysis techniques available to describe dynamic measurement characteristics are reviewed. Time domain and spectral methods are described, and statistical classification in terms of moments is discussed. Several of these waveform analysis techniques have been implemented on a computer and applied to dynamc signals. A laboratory evaluation of the methods with respect to signal detection capability is described. A unique coherence function (the hyper-coherence) was developed through the course of this investigation, which appears promising as a diagnostic tool. This technique and several other non-linear methods of signal analysis are presented and illustrated by application. Software for application of these techniques has been installed on the signal processing system at the NASA/MSFC Systems Dynamics Laboratory.

Roller Bearing Health Monitoring Using CPLE Frequency Analysis Method

NASA Technical Reports Server (NTRS)

Jong, Jen-Yi; Jones, Jess H.

2007-01-01

This paper describes a unique vibration signature analysis technique Coherence Phase Line Enhancer (CPLE) Frequency Analysis - for roller bearing health monitoring. Defects of roller bearing (e.g. wear, foreign debris, crack in bearing supporting structure, etc.) can cause small bearing characteristic frequency shifts due to minor changes in bearing geometry. Such frequency shifts are often too small to detect by the conventional Power Spectral Density (PSD) due to its frequency bandwidth limitation. This Coherent Phase Line Enhancer technology has been evolving over the last few years and has culminated in the introduction of a new and novel frequency spectrum which is fully described in this paper. This CPLE technology uses a "key phasor" or speed probe as a preprocessor for this analysis. With the aid of this key phasor, this CPLE technology can develop a two dimensional frequency spectrum that preserves both amplitude and phase that is not normally obtained using conventional frequency analysis. This two-dimensional frequency transformation results in several newly defined spectral functions; i. e. CPLE-PSD, CPLE-Coherence and the CPLE-Frequency. This paper uses this CPLE frequency analysis to detect subtle, low level bearing related signals in the High Pressure Fuel Pump (HPFP) of the Space Shuttle Main Engine (SSME). For many rotating machinery applications, a key phasor is an essential measurement that is used in the detection of bearing related signatures. There are times however, when a key phasor is not available; i. e. during flight of any of the SSME turbopumps or on the SSME High Pressure Oxygen Turbopump (HPOTP) where no speed probe is present. In this case, the CPLE analysis approach can still be achieved using a novel Pseudo Key Phasor (PKP) technique to reconstruct a 1/Rev PKP signal directly from external vibration measurements. This paper develops this Pseudo Key Phasor technique and applies it to the SSME vibration data.

Investigation of the transient fuel preburner manifold and combustor

NASA Technical Reports Server (NTRS)

Wang, Ten-See; Chen, Yen-Sen; Farmer, Richard C.

1989-01-01

A computational fluid dynamics (CFD) model with finite rate reactions, FDNS, was developed to study the start transient of the Space Shuttle Main Engine (SSME) fuel preburner (FPB). FDNS is a time accurate, pressure based CFD code. An upwind scheme was employed for spatial discretization. The upwind scheme was based on second and fourth order central differencing with adaptive artificial dissipation. A state of the art two-equation k-epsilon (T) turbulence model was employed for the turbulence calculation. A Pade' Rational Solution (PARASOL) chemistry algorithm was coupled with the point implicit procedure. FDNS was benchmarked with three well documented experiments: a confined swirling coaxial jet, a non-reactive ramjet dump combustor, and a reactive ramjet dump combustor. Excellent comparisons were obtained for the benchmark cases. The code was then used to study the start transient of an axisymmetric SSME fuel preburner. Predicted transient operation of the preburner agrees well with experiment. Furthermore, it was also found that an appreciable amount of unburned oxygen entered the turbine stages.

Develop Advanced Nonlinear Signal Analysis Topographical Mapping System

NASA Technical Reports Server (NTRS)

Jong, Jen-Yi

1997-01-01

During the development of the SSME, a hierarchy of advanced signal analysis techniques for mechanical signature analysis has been developed by NASA and AI Signal Research Inc. (ASRI) to improve the safety and reliability for Space Shuttle operations. These techniques can process and identify intelligent information hidden in a measured signal which is often unidentifiable using conventional signal analysis methods. Currently, due to the highly interactive processing requirements and the volume of dynamic data involved, detailed diagnostic analysis is being performed manually which requires immense man-hours with extensive human interface. To overcome this manual process, NASA implemented this program to develop an Advanced nonlinear signal Analysis Topographical Mapping System (ATMS) to provide automatic/unsupervised engine diagnostic capabilities. The ATMS will utilize a rule-based Clips expert system to supervise a hierarchy of diagnostic signature analysis techniques in the Advanced Signal Analysis Library (ASAL). ASAL will perform automatic signal processing, archiving, and anomaly detection/identification tasks in order to provide an intelligent and fully automated engine diagnostic capability. The ATMS has been successfully developed under this contract. In summary, the program objectives to design, develop, test and conduct performance evaluation for an automated engine diagnostic system have been successfully achieved. Software implementation of the entire ATMS system on MSFC's OISPS computer has been completed. The significance of the ATMS developed under this program is attributed to the fully automated coherence analysis capability for anomaly detection and identification which can greatly enhance the power and reliability of engine diagnostic evaluation. The results have demonstrated that ATMS can significantly save time and man-hours in performing engine test/flight data analysis and performance evaluation of large volumes of dynamic test data.

Structural application of high strength, high temperature ceramics

NASA Technical Reports Server (NTRS)

Hall, W. B.

1982-01-01

The operation of rocket engine turbine pumps is limited by the temperature restrictions of metallic components used in the systems. Mechanical strength and stability of these metallic components decrease drastically at elevated temperatures. Ceramic materials that retain high strength at high temperatures appear to be a feasible alternate material for use in the hot end of the turbopumps. This project identified and defined the processing parameters that affected the properties of Si3N4, one of candidate ceramic materials. Apparatus was assembled and put into operation to hot press Si3N4 powders into bulk material for in house evaluation. A work statement was completed to seek outside contract services to design, manufacture, and evaluate Si3N4 components in the service environments that exists in SSME turbopumps.

High-temperature, high-pressure optical port for rocket engine applications

NASA Technical Reports Server (NTRS)

Delcher, Ray; Nemeth, ED; Powers, W. T.

1993-01-01

This paper discusses the design, fabrication, and test of a window assembly for instrumentation of liquid-fueled rocket engine hot gas systems. The window was designed to allow optical measurements of hot gas in the SSME fuel preburner and appears to be the first window designed for application in a rocket engine hot gas system. Such a window could allow the use of a number of remote optical measurement technologies including: Raman temperature and species concentration measurement, Raleigh temperature measurements, flame emission monitoring, flow mapping, laser-induced florescence, and hardware imaging during engine operation. The window assembly has been successfully tested to 8,000 psi at 1000 F and over 11,000 psi at room temperature. A computer stress analysis shows the window will withstand high temperature and cryogenic thermal shock.

Last SSME test on A-1

NASA Image and Video Library

2006-09-29

The Stennis Space Center conducted the final space shuttle main engine test on its A-1 Test Stand Friday. The A-1 Test Stand was the site of the first test on a shuttle main engine in 1975. Stennis will continue testing shuttle main engines on its A-2 Test Stand through the end of the Space Shuttle Program in 2010. The A-1 stand begins a new chapter in its operational history in October. It will be temporarily decommissioned to convert it for testing the J-2X engine, which will power the upper stage of NASA's new crew launch vehicle, the Ares I. Although this ends the stand's work on the Space Shuttle Program, it will soon be used for the rocket that will carry America's next generation human spacecraft, Orion.

Methane heat transfer investigation

NASA Technical Reports Server (NTRS)

1984-01-01

Future high chamber pressure LOX/hydrocarbon booster engines require copper base alloy main combustion chamber coolant channels similar to the SSME to provide adequate cooling and reusable engine life. Therefore, it is of vital importance to evaluate the heat transfer characteristics and coking thresholds for LNG (94% methane) cooling, with a copper base alloy material adjacent to he fuel coolant. High pressure methane cooling and coking characteristics recently evaluated at Rocketdyne using stainless steel heated tubes at methane bulk temperatures and coolant wall temperatures typical of advanced engine operation except at lower heat fluxes as limited by the tube material. As expected, there was no coking observed. However, coking evaluations need be conducted with a copper base surface exposed to the methane coolant at higher heat fluxes approaching those of future high chamber pressure engines.

A Three Dimensional Parallel Time Accurate Turbopump Simulation Procedure Using Overset Grid Systems

NASA Technical Reports Server (NTRS)

Kiris, Cetin; Chan, William; Kwak, Dochan

2001-01-01

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and non-uniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

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.

Beta 2: A near term, fully reusable, horizontal takeoff and landing two-stage-to-orbit launch vehicle concept

NASA Technical Reports Server (NTRS)

Burkardt, Leo A.

1992-01-01

A recent study has confirmed the feasibility of a near term, fully reusable, horizontal takeoff and landing two-stage-to-orbit (TSTO) launch vehicle concept. The vehicle stages at Mach 6.5. The first stage is powered by a turboramjet propulsion system with the turbojets being fueled by JP and the ramjet by LH2. The second stage is powered by a space shuttle main engine (SSME) rocket engine. For about the same gross weight as growth versions of the 747, the vehicle can place 10,000 lbm. in low polar orbit or 16,000 lbm. to Space Station Freedom.

Advanced transportation system studies technical area 3: Alternate propulsion subsystem concepts, volume 2

NASA Technical Reports Server (NTRS)

Levak, Daniel

1993-01-01

The Alternate Propulsion Subsystem Concepts contract had five tasks defined for the first year. The tasks were: F-1A Restart Study, J-2S Restart Study, Propulsion Database Development, Space Shuttle Main Engine (SSME) Upper Stage Use, and CER's for Liquid Propellant Rocket Engines. The detailed study results, with the data to support the conclusions from various analyses, are being reported as a series of five separate Final Task Reports. Consequently, this volume only reports the required programmatic information concerning Computer Aided Design Documentation, and New Technology Reports. A detailed Executive Summary, covering all the tasks, is also available as Volume 1.

Interaction of external conditions with the internal flowfield in liquid rocket engines - A computational study

NASA Technical Reports Server (NTRS)

Trinh, H. P.; Gross, K. W.

1989-01-01

Computational studies have been conducted to examine the capability of a CFD code by simulating the steady state thrust chamber internal flow. The SSME served as the sample case, and significant parameter profiles are presented and discussed. Performance predictions from TDK, the recommended JANNAF reference computer program, are compared with those from PHOENICS to establish the credibility of its results. The investigation of an overexpanded nozzle flow is particularly addressed since it plays an important role in the area ratio selection of future rocket engines. Experience gained during this uncompleted flow separation study and future steps are outlined.

Incompressible Navier-Stokes Solvers in Primative Variables and their Applications to Steady and Unsteady Flow Simulations

NASA Technical Reports Server (NTRS)

Kiris, Cetin C.; Kwak, Dochan; Rogers, Stuart E.

2002-01-01

This paper reviews recent progress made in incompressible Navier-Stokes simulation procedures and their application to problems of engineering interest. Discussions are focused on the methods designed for complex geometry applications in three dimensions, and thus are limited to primitive variable formulation. A summary of efforts in flow solver development is given followed by numerical studies of a few example problems of current interest. Both steady and unsteady solution algorithms and their salient features are discussed. Solvers discussed here are based on a structured-grid approach using either a finite -difference or a finite-volume frame work. As a grand-challenge application of these solvers, an unsteady turbopump flow simulation procedure has been developed which utilizes high performance computing platforms. In the paper, the progress toward the complete simulation capability of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of two parallel computing algorithms that have been implemented in the INS3D code. The relative motion of the grid systems for the rotorstator interaction was obtained using overact grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on SCSI Origin 3000 systems at NASA Ames Research Center. The same procedure has been extended to the development of NASA-DeBakey Ventricular Assist Device (VAD) that is based on an axial blood pump. Computational, and clinical analysis of this device are presented.

Role of Process Control in Improving Space Vehicle Safety A Space Shuttle External Tank Example

NASA Technical Reports Server (NTRS)

Safie, Fayssal M.; Nguyen, Son C.; Burleson, Keith W.

2006-01-01

Developing a safe and reliable space vehicle requires good design and good manufacturing, or in other words "design it right and build it right". A great design can be hard to build or manufacture mainly due to difficulties related to quality. Specifically, process control can be a challenge. As a result, the system suffers from low quality which leads to low reliability and high system risk. The Space Shuttle has experienced some of those cases, but has overcome these difficulties through extensive redesign efforts and process enhancements. One example is the design of the hot gas temperature sensor on the Space Shuttle Main Engine (SSME), which resulted in failure of the sensor in flight and led to a redesign of the sensor. The most recent example is the Space Shuttle External Tank (ET) Thermal Protection System (TPS) reliability issues that contributed to the Columbia accident. As a result, extensive redesign and process enhancement activities have been performed over the last two years to minimize the sensitivities and difficulties of the manual TPS application process.

Shuttle Derived In-Line Heavy Lift Vehicle

NASA Technical Reports Server (NTRS)

Greenwood, Terry; Twichell, Wallace; Ferrari, Daniel; Kuck, Frederick

2005-01-01

This paper introduces an evolvable Space Shuttle derived family of launch vehicles. It details the steps in the evolution of the vehicle family, noting how the evolving lift capability compares with the evolving lift requirements. A system description is given for each vehicle. The cost of each development stage is described. Also discussed are demonstration programs, the merits of the SSME vs. an expendable rocket engine (RS-68), and finally, the next steps needed to refine this concept.

Evaluation of undeveloped rocket engine cycle applications to advanced transportation

NASA Technical Reports Server (NTRS)

1990-01-01

Undeveloped pump-fed, liquid propellant rocket engine cycles were assessed and evaluated for application to Next Manned Transportation System (NMTS) vehicles, which would include the evolving Space Transportation System (STS Evolution), the Personnel Launch System (PLS), and the Advanced Manned Launch System (AMLS). Undeveloped engine cycles selected for further analysis had potential for increased reliability, more maintainability, reduced cost, and improved (or possibly level) performance when compared to the existing SSME and proposed STME engines. The split expander (SX) cycle, the full flow staged combustion (FFSC) cycle, and a hybrid version of the FFSC, which has a LOX expander drive for the LOX pump, were selected for definition and analysis. Technology requirements and issues were identified and analyses of vehicle systems weight deltas using the SX and FFSC cycles in AMLS vehicles were performed. A strawman schedule and cost estimate for FFSC subsystem technology developments and integrated engine system demonstration was also provided.

Reusable Rocket Engine Turbopump Health Management System

NASA Technical Reports Server (NTRS)

Surko, Pamela

1994-01-01

A health monitoring expert system software architecture has been developed to support condition-based health monitoring of rocket engines. Its first application is in the diagnosis decisions relating to the health of the high pressure oxidizer turbopump (HPOTP) of Space Shuttle Main Engine (SSME). The post test diagnostic system runs off-line, using as input the data recorded from hundreds of sensors, each running typically at rates of 25, 50, or .1 Hz. The system is invoked after a test has been completed, and produces an analysis and an organized graphical presentation of the data with important effects highlighted. The overall expert system architecture has been developed and documented so that expert modules analyzing other line replaceable units may easily be added. The architecture emphasizes modularity, reusability, and open system interfaces so that it may be used to analyze other engines as well.

Composite Load Spectra for Select Space Propulsion Structural Components

NASA Technical Reports Server (NTRS)

Ho, Hing W.; Newell, James F.

1994-01-01

Generic load models are described with multiple levels of progressive sophistication to simulate the composite (combined) load spectra (CLS) that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades and liquid oxygen (LOX) posts. These generic (coupled) models combine the deterministic models for composite load dynamic, acoustic, high-pressure and high rotational speed, etc., load simulation using statistically varying coefficients. These coefficients are then determined using advanced probabilistic simulation methods with and without strategically selected experimental data. The entire simulation process is included in a CLS computer code. Applications of the computer code to various components in conjunction with the PSAM (Probabilistic Structural Analysis Method) to perform probabilistic load evaluation and life prediction evaluations are also described to illustrate the effectiveness of the coupled model approach.

STS-54 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1993-01-01

The STS-54 Space Shuttle Program Mission Report is a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle Main Engine (SSME) subsystems performance during this fifty-third flight of the Space Shuttle Program, and the third flight of the Orbiter vehicle Endeavour (OV-105). In addition to the Orbiter, the flight vehicle consisted of an ET, which was designated ET-51; three SSME's, which were serial numbers 2019, 2033, and 2018 in positions 1, 2, and 3, respectively; and two retrievable and reusable SRB's which were designated BI-056. The lightweight RSRM's that were installed in each SRB were designated 360L029A for the left SRB, and 360L029B for the right SRB. The primary objectives of this flight were to perform the operations to deploy the Tracking and Data Relay Satellite-F/Inertial Upper Stage payload and to fulfill the requirements of the Diffuse X-Ray Spectrometer (DXS) payload. The secondary objective was to fly the Chromosome and Plant Cell Division in Space (CHROMEX), Commercial Generic Bioprocessing Apparatus (CGBA), Physiological and Anatomical Rodent Experiment (PARE), and the Solid Surface Combustion Experiment (SSCE). In addition to presenting a summary of subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. The official tracking number for each in-flight anomaly, assigned by the cognizant project, is also shown. All times are given in Greenwich mean time (G.m.t.) and mission elapsed time (MET).

Turning Fiction Into Non-fiction for Signal-to-Noise Ratio Estimation -- The Time-Multiplexed and Adaptive Split-Symbol Moments Estimator

NASA Astrophysics Data System (ADS)

Simon, M.; Dolinar, S.

2005-08-01

A means is proposed for realizing the generalized split-symbol moments estimator (SSME) of signal-to-noise ratio (SNR), i.e., one whose implementation on the average allows for a number of subdivisions (observables), 2L, per symbol beyond the conventional value of two, with other than an integer value of L. In theory, the generalized SSME was previously shown to yield optimum performance for a given true SNR, R, when L=R/sqrt(2) and thus, in general, the resulting estimator was referred to as the fictitious SSME. Here we present a time-multiplexed version of the SSME that allows it to achieve its optimum value of L as above (to the extent that it can be computed as the average of a sum of integers) at each value of SNR and as such turns fiction into non-fiction. Also proposed is an adaptive algorithm that allows the SSME to rapidly converge to its optimum value of L when in fact one has no a priori information about the true value of SNR.

Enhancements to the Engine Data Interpretation System (EDIS)

NASA Technical Reports Server (NTRS)

Hofmann, Martin O.

1993-01-01

The Engine Data Interpretation System (EDIS) expert system project assists the data review personnel at NASA/MSFC in performing post-test data analysis and engine diagnosis of the Space Shuttle Main Engine (SSME). EDIS uses knowledge of the engine, its components, and simple thermodynamic principles instead of, and in addition to, heuristic rules gathered from the engine experts. EDIS reasons in cooperation with human experts, following roughly the pattern of logic exhibited by human experts. EDIS concentrates on steady-state static faults, such as small leaks, and component degradations, such as pump efficiencies. The objective of this contract was to complete the set of engine component models, integrate heuristic rules into EDIS, integrate the Power Balance Model into EDIS, and investigate modification of the qualitative reasoning mechanisms to allow 'fuzzy' value classification. The results of this contract is an operational version of EDIS. EDIS will become a module of the Post-Test Diagnostic System (PTDS) and will, in this context, provide system-level diagnostic capabilities which integrate component-specific findings provided by other modules.

Enhancements to the Engine Data Interpretation System (EDIS)

NASA Technical Reports Server (NTRS)

Hofmann, Martin O.

1993-01-01

The Engine Data Interpretation System (EDIS) expert system project assists the data review personnel at NASA/MSFC in performing post-test data analysis and engine diagnosis of the Space Shuttle Main Engine (SSME). EDIS uses knowledge of the engine, its components, and simple thermodynamic principles instead of, and in addition to, heuristic rules gathered from the engine experts. EDIS reasons in cooperation with human experts, following roughly the pattern of logic exhibited by human experts. EDIS concentrates on steady-state static faults, such as small leaks, and component degradations, such as pump efficiencies. The objective of this contract was to complete the set of engine component models, integrate heuristic rules into EDIS, integrate the Power Balance Model into EDIS, and investigate modification of the qualitative reasoning mechanisms to allow 'fuzzy' value classification. The result of this contract is an operational version of EDIS. EDIS will become a module of the Post-Test Diagnostic System (PTDS) and will, in this context, provide system-level diagnostic capabilities which integrate component-specific findings provided by other modules.

Thermal and Structural Analysis of a Hollow Core Space Shuttle Main Engine (SSME) Turbine Blade

NASA Technical Reports Server (NTRS)

Abdul-Aziz, Ali; Kalluri, Sreeramesh; McGaw, Michael A.

1995-01-01

The influence of primary and secondary orientations on the elastic response of a hollow core, (001)-oriented nickel base single-crystal superalloy turbine blade, was investigated under combined thermal and mechanical conditions. Finite element techniques is employed through MARC finite element code to conduct the analyses on a hollow core SSME turbine blade made out of PWA 1480 single crystal material. Primary orientation of the single crystal superalloy was varied in increments of 2 deg, from 0 to 10 deg, from the (001) direction. Two secondary orientations (0 and 45 deg) were considered with respect to the global coordinate system, as the primary orientation angle was varied. The stresses developed within the single crystal blade were determined for different orientations of the blade. The influence of angular offsets such as the single crystal's primary and secondary orientations and the loading conditions on the elastic stress response of the PWA 1480 hollow blade are summarized. The influence of he primary orientation angle, when constrained between the bounds considered, was not found to be as significant as the influence of the secondary orientation angle.

Vortex shedding flow meter performance at high flow velocities

NASA Technical Reports Server (NTRS)

Siegwarth, J. D.

1986-01-01

In some of the ducts of the Space Shuttle Main Engine (SSME), the maximum liquid oxygen flow velocities approach 10 times those at which liquid flow measurements are normally made. The hydrogen gas flow velocities in other ducts exceed the maximum for gas flow measurement by more than a factor of 3. The results presented here show from water flow tests that vortex shedding flow meters of the appropriate design can measure water flow to velocities in excess of 55 m/s, which is a Reynolds number of about 2 million. Air flow tests have shown that the same meter can measure flow to a Reynolds number of at least 22 million. Vortex shedding meters were installed in two of the SSME ducts and tested with water flow. Narrow spectrum lines were obtained and the meter output frequencies were proportional to flow to + or - 0.5% or better over the test range with no flow conditioning, even though the ducts had multiple bends preceeding the meter location. Meters with the shedding elements only partially spanning the pipe and some meters with ring shaped shedding elements were also tested.

An experimental investigation of rubbing interaction in labyrinth seals at cryogenic temperature

NASA Technical Reports Server (NTRS)

Dolan, F. X.; Kennedy, F. E.; Schulson, E. M.

1985-01-01

An experimental program was carried out to address issues related to the observed cracking of the titanium knife edges on the labyrinth seals of the high pressure fuel pump (HPFP) in the Space Shuttle main engine (SSME). Thermal shock experiments were carried out using a jet specimen with geometry similar to the knife edge geometry. These tests demonstrate that cracking of the titanium alloy is possible in a situation involving repeated thermal cycles over a wide temperature range, as might be realized during a rub in the liquid hydrogen fuel pump. High speed rub interaction tests were conducted using a representative knife edge and seal geometry over a broad range of interaction rates. Alternative materials were also experimentally evaluated. These tests provide information which can be used to design improved labyrinth seals for the HPFP of the SSME. In particular, plasma-sprayed aluminum-graphite was found to be significantly better than aluminum alloy seals used at present from the standpoint of rub performance. Ion nitriding of the titanium alloy knife edges was also found to improve rub performance compared with the untreated baseline knife edge material.

STS-57 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1993-01-01

The STS-57 Space Shuttle Program Mission Report provides a summary of the Payloads, as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the fifty-sixth flight of the Space Shuttle Program and fourth flight of the Orbiter vehicle Endeavour (OV-105). In addition to the Orbiter, the flight vehicle consisted of an ET (ET-58); three SSME's which were designated as serial numbers 2019, 2034, and 2017 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-059. The lightweight RSRM's that were installed in each SRB were designated as 360L032A for the left SRB and 360W032B for the right SRB. The STS-57 Space Shuttle Program Mission Report fulfills the Space Shuttle Program requirement, as documented in NSTS 07700, Volume 8, Appendix E. That document states that each major organizational element supporting the Program will report the results of their hardware evaluation and mission performance plus identify all related in-flight anomalies.

Implementation of a data management software system for SSME test history data

NASA Technical Reports Server (NTRS)

Abernethy, Kenneth

1986-01-01

The implementation of a software system for managing Space Shuttle Main Engine (SSME) test/flight historical data is presented. The software system uses the database management system RIM7 for primary data storage and routine data management, but includes several FORTRAN programs, described here, which provide customized access to the RIM7 database. The consolidation, modification, and transfer of data from the database THIST, to the RIM7 database THISRM is discussed. The RIM7 utility modules for generating some standard reports from THISRM and performing some routine updating and maintenance are briefly described. The FORTRAN accessing programs described include programs for initial loading of large data sets into the database, capturing data from files for database inclusion, and producing specialized statistical reports which cannot be provided by the RIM7 report generator utility. An expert system tutorial, constructed using the expert system shell product INSIGHT2, is described. Finally, a potential expert system, which would analyze data in the database, is outlined. This system could use INSIGHT2 as well and would take advantage of RIM7's compatibility with the microcomputer database system RBase 5000.

Heat transfer in rocket engine combustion chambers and regeneratively cooled nozzles

NASA Technical Reports Server (NTRS)

1993-01-01

A conjugate heat transfer computational fluid dynamics (CFD) model to describe regenerative cooling in the main combustion chamber and nozzle and in the injector faceplate region for a launch vehicle class liquid rocket engine was developed. An injector model for sprays which treats the fluid as a variable density, single-phase media was formulated, incorporated into a version of the FDNS code, and used to simulate the injector flow typical of that in the Space Shuttle Main Engine (SSME). Various chamber related heat transfer analyses were made to verify the predictive capability of the conjugate heat transfer analysis provided by the FDNS code. The density based version of the FDNS code with the real fluid property models developed was successful in predicting the streamtube combustion of individual injector elements.

Fault Management Technology Maturation for NASA's Constellation Program

NASA Technical Reports Server (NTRS)

Waterman, Robert D.

2010-01-01

This slide presentation reviews the maturation of fault management technology in preparation for the Constellation Program. There is a review of the Space Shuttle Main Engine (SSME) and a discussion of a couple of incidents with the shuttle main engine and tanking that indicated the necessity for predictive maintenance. Included is a review of the planned Ares I-X Ground Diagnostic Prototype (GDP) and further information about detection and isolation of faults using Testability Engineering and Maintenance System (TEAMS). Another system that being readied for use that detects anomalies, the Inductive Monitoring System (IMS). The IMS automatically learns how the system behaves and alerts operations it the current behavior is anomalous. The comparison of STS-83 and STS-107 (i.e., the Columbia accident) is shown as an example of the anomaly detection capabilities.

Probabilistic Structural Analysis Methods for select space propulsion system components (PSAM). Volume 3: Literature surveys and technical reports

NASA Technical Reports Server (NTRS)

1992-01-01

The technical effort and computer code developed during the first year are summarized. Several formulations for Probabilistic Finite Element Analysis (PFEA) are described with emphasis on the selected formulation. The strategies being implemented in the first-version computer code to perform linear, elastic PFEA is described. The results of a series of select Space Shuttle Main Engine (SSME) component surveys are presented. These results identify the critical components and provide the information necessary for probabilistic structural analysis.

Simulations of Flow Through the SSME LH2 Feed Line and LPFP Inducer

NASA Technical Reports Server (NTRS)

Dorney, Daniel J.; Rothermel, Jeffry

2003-01-01

During a post-flight inspection of the liquid hydrogen feed lines leading the Space Shuttle main engines cracks were discover in slots on a flow liner just upstream of the low pressure fuel pump inducer. Numerical simulations have been performed for the feed line, the flow liner (including the slots and backing cavity) and the inducer. The predicted results have been compared with experimental data taken during hot-fire tests at NASA Stennis Space Center.

Application of powder metallurgy technique to produce improved bearing elements for cryogenic aerospace engine turbopumps

NASA Technical Reports Server (NTRS)

Moxson, V. S.; Moracz, D. J.; Bhat, B. N.; Dolan, F. J.; Thom, R.

1987-01-01

Traditionally, vacuum melted 440C stainless steel is used for high performance bearings for aerospace cryogenic systems where corrosion due to condensation is a major concern. For the Space Shuttle Main Engine (SSME), however, 440C performance in the high-pressure turbopumps has been marginal. A basic assumption of this study was that powder metallurgy, rather than cast/wrought, processing would provide the finest, most homogeneous bearing alloy structure. Preliminary testing of P/M alloys (hardness, corrosion resistance, wear resistance, fatigue resistance, and fracture toughness) was used to 'de-select' alloys which did perform as well as baseline 440C. Five out of eleven candidate materials (14-4/6V, X-405, MRC-2001, T-440V, and D-5) based on preliminary screening were selected for the actual rolling-sliding five-ball testing. The results of this test were compared with high-performance vacuum-melted M50 bearing steel. The results of the testing indicated outstanding performance of two P/M alloys, X-405 and MRC-2001, which eventually will be further evaluated by full-scale bearing testing.

Space Shuttle Main Engine (SSME) LOX turbopump pump-end bearing analysis

NASA Technical Reports Server (NTRS)

1986-01-01

A simulation of the shaft/bearing system of the Space Shuttle Main Engine Liquid Oxygen turbopump was developed. The simulation model allows the thermal and mechanical characteristics to interact as a realistic simulation of the bearing operating characteristics. The model accounts for single and two phase coolant conditions, and includes the heat generation from bearing friction and fluid stirring. Using the simulation model, parametric analyses were performed on the 45 mm pump-end bearings to investigate the sensitivity of bearing characteristics to contact friction, axial preload, coolant flow rate, coolant inlet temperature and quality, heat transfer coefficients, outer race clearance and misalignment, and the effects of thermally isolating the outer race from the isolator.

Flame trench analysis of NLS vehicles

NASA Technical Reports Server (NTRS)

Zeytinoglu, Nuri

1993-01-01

The present study takes the initial steps of establishing a better flame trench design criteria for future National Launch System vehicles. A three-dimensional finite element computer model for predicting the transient thermal and structural behavior of the flame trench walls was developed using both I-DEAS and MSC/NASTRAN software packages. The results of JANNAF Standardized Plume flowfield calculations of sea-level exhaust plume of the Space Shuttle Main Engine (SSME), Space Transportation Main Engine (STME), and Advanced Solid Rocket Motors (ASRM) were analyzed for different axial distances. The results of sample calculations, using the developed finite element model, are included. The further suggestions are also reported for enhancing the overall analysis of the flame trench model.

Determination of Uncertainties for the New SSME Model

NASA Technical Reports Server (NTRS)

Coleman, Hugh W.; Hawk, Clark W.

1996-01-01

This report discusses the uncertainty analysis performed in support of a new test analysis and performance prediction model for the Space Shuttle Main Engine. The new model utilizes uncertainty estimates for experimental data and for the analytical model to obtain the most plausible operating condition for the engine system. This report discusses the development of the data sets and uncertainty estimates to be used in the development of the new model. It also presents the application of uncertainty analysis to analytical models and the uncertainty analysis for the conservation of mass and energy balance relations is presented. A new methodology for the assessment of the uncertainty associated with linear regressions is presented.

Overview of aerothermodynamic loads definition study

NASA Technical Reports Server (NTRS)

Gaugler, Raymond E.

1991-01-01

The objective of the Aerothermodynamic Loads Definition Study is to develop methods of accurately predicting the operating environment in advanced Earth-to-Orbit (ETO) propulsion systems, such as the Space Shuttle Main Engine (SSME) powerhead. Development of time averaged and time dependent three dimensional viscous computer codes as well as experimental verification and engine diagnostic testing are considered to be essential in achieving that objective. Time-averaged, nonsteady, and transient operating loads must all be well defined in order to accurately predict powerhead life. Described here is work in unsteady heat flow analysis, improved modeling of preburner flow, turbulence modeling for turbomachinery, computation of three dimensional flow with heat transfer, and unsteady viscous multi-blade row turbine analysis.

A combined Eulerian-Lagrangian two-phase flow analysis of SSME HPOTP nozzle plug trajectories. II - Results

NASA Technical Reports Server (NTRS)

Mcconnaughey, P. K.; Garcia, R.; Dejong, F. J.; Sabnis, J. S.; Pribik, D. A.

1989-01-01

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

System for Anomaly and Failure Detection (SAFD) system development

NASA Technical Reports Server (NTRS)

Oreilly, D.

1992-01-01

This task specified developing the hardware and software necessary to implement the System for Anomaly and Failure Detection (SAFD) algorithm, developed under Technology Test Bed (TTB) Task 21, on the TTB engine stand. This effort involved building two units; one unit to be installed in the Block II Space Shuttle Main Engine (SSME) Hardware Simulation Lab (HSL) at Marshall Space Flight Center (MSFC), and one unit to be installed at the TTB engine stand. Rocketdyne personnel from the HSL performed the task. The SAFD algorithm was developed as an improvement over the current redline system used in the Space Shuttle Main Engine Controller (SSMEC). Simulation tests and execution against previous hot fire tests demonstrated that the SAFD algorithm can detect engine failure as much as tens of seconds before the redline system recognized the failure. Although the current algorithm only operates during steady state conditions (engine not throttling), work is underway to expand the algorithm to work during transient condition.

Rocket Engine Innovations Advance Clean Energy

NASA Technical Reports Server (NTRS)

2012-01-01

During launch countdown, at approximately T-7 seconds, the Space Shuttle Main Engines (SSMEs) roar to life. When the controllers indicate normal operation, the solid rocket boosters ignite and the shuttle blasts off. Initially, the SSMEs throttle down to reduce stress during the period of maximum dynamic pressure, but soon after, they throttle up to propel the orbiter to 17,500 miles per hour. In just under 9 minutes, the three SSMEs burn over 1.6 million pounds of propellant, and temperatures inside the main combustion chamber reach 6,000 F. To cool the engines, liquid hydrogen circulates through miles of tubing at -423 F. From 1981to 2011, the Space Shuttle fleet carried crew and cargo into orbit to perform a myriad of unprecedented tasks. After 30 years and 135 missions, the feat of engineering known as the SSME boasted a 100-percent flight success rate.

Installation of TVC Actuators in a Two Axis Inertial Load Simulator Test Stand

NASA Technical Reports Server (NTRS)

Dziubanek, Adam

2013-01-01

This paper is about the installation of Space Shuttle Main Engines (SSME) actuators in the new Two Axis Inertial Load Simulator (ILS) at MSFC. The new test stand will support the core stage of the Space Launch System (SLS). Because of the unique geometry of the new test stand standard actuator installation procedures will not work. I have been asked to develop a design on how to install the actuators into the new test stand. After speaking with the engineers and technicians I have created a possible design solution. Using Pro Engineer design software and running my own stress calculations I have proven my design is feasible. I have learned how to calculate the stresses my design will see from this task. From the calculations I have learned I have over built the apparatus. I have also expanded my knowledge of Pro Engineer and was able to create a model of my idea.

Application of Single Crystal Failure Criteria: Theory and Turbine Blade Case Study

NASA Technical Reports Server (NTRS)

Sayyah, Tarek; Swanson, Gregory R.; Schonberg, W. P.

1999-01-01

The orientation of the single crystal material within a structural component is known to affect the strength and life of the part. The first stage blade of the High Pressure Fuel Turbopump (HPFTP)/ Alternative Turbopump Development (ATD), of the Space Shuttle Main Engine (SSME) was used to study the effects of secondary axis'orientation angles on the failure rate of the blade. A new failure criterion was developed based on normal and shear strains on the primary crystallographic planes. The criterion was verified using low cycle fatigue (LCF) specimen data and a finite element model of the test specimens. The criterion was then used to study ATD/HPFTP first stage blade failure events. A detailed ANSYS finite element model of the blade was used to calculate the failure parameter for the different crystallographic orientations. A total of 297 cases were run to cover a wide range of acceptable orientations within the blade. Those orientations are related to the base crystallographic coordinate system that was created in the ANSYS finite element model. Contour plots of the criterion as a function of orientation for the blade tip and attachment were obtained. Results of the analysis revealed a 40% increase in the failure parameter due to changing of the primary and secondary axes of material orientations. A comparison between failure criterion predictions and actual engine test data was then conducted. The engine test data comes from two ATD/HPFTP builds (units F3- 4B and F6-5D), which were ground tested on the SSME at the Stennis Space Center in Mississippi. Both units experienced cracking of the airfoil tips in multiple blades, but only a few cracks grew all the way across the wall of the hollow core airfoil.

Unsteady Turbopump Flow Simulations

NASA Technical Reports Server (NTRS)

Centin, Kiris C.; Kwak, Dochan

2001-01-01

The objective of the current effort is two-fold: 1) to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine; and 2) to provide high-fidelity unsteady turbopump flow analysis capability to support the design of pump sub-systems for advanced space transportation vehicle. Since the space launch systems in the near future are likely to involve liquid propulsion system, increasing the efficiency and reliability of the turbopump components is an important task. To date, computational tools for design/analysis of turbopump flow are based on relatively lower fidelity methods. Unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available, at least, for real-world engineering applications. Present effort is an attempt to provide this capability so that developers of the vehicle will be able to extract such information as transient flow phenomena for start up, impact of non-uniform inflow, system vibration and impact on the structure. Those quantities are not readily available from simplified design tools. In this presentation, the progress being made toward complete turbo-pump simulation capability for a liquid rocket engine is reported. Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for the performance evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. Relative motion of the grid system for rotor-stator interaction was obtained by employing overset grid techniques. Time-accuracy of the scheme has been evaluated by using simple test cases. Unsteady computations for SSME turbopump, which contains 106 zones with 34.5 Million grid points, are currently underway on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability and the performance of the parallel versions of the code will be presented.

Next-Generation RS-25 Engines for the NASA Space Launch System

NASA Technical Reports Server (NTRS)

Ballard, Richard O.

2017-01-01

The utilization of heritage RS-25 engines, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over 1 million seconds total accumulated hot-fire time. In addition, there were also 16 flight engines and 2 development engines remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway to improve system affordability and eliminate obsolescence concerns. These key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Powder metallurgy bearings for advanced rocket engines

NASA Technical Reports Server (NTRS)

Fleck, J. N.; Killman, B. J.; Munson, H.E.

1985-01-01

Traditional ingot metallurgy was pushed to the limit for many demanding applications including antifriction bearings. New systems require corrosion resistance, better fatigue resistance, and higher toughness. With conventional processing, increasing the alloying level to achieve corrosion resistance results in a decrease in other properties such as toughness. Advanced powder metallurgy affords a viable solution to this problem. During powder manufacture, the individual particle solidifies very rapidly; as a consequence, the primary carbides are very small and uniformly distributed. When properly consolidated, this uniform structure is preserved while generating a fully dense product. Element tests including rolling contact fatigue, hot hardness, wear, fracture toughness, and corrosion resistance are underway on eleven candidate P/M bearing alloys and results are compared with those for wrought 440C steel, the current SSME bearing material. Several materials which offer the promise of a significant improvement in performance were identified.

STS-55 Columbia, Orbiter Vehicle (OV) 102, SSME abort at KSC LC Pad 39A

NASA Image and Video Library

1993-03-22

S93-31601 (March 1993) --- The second Space Shuttle launch attempt of 1993 comes to an abrupt halt when one of the three main engines on the orbiter Columbia shuts down at T -3 seconds, resulting in an on-the-pad abort of Mission STS-55. This was the first time in the post-Challenger era that a main engine shutdown has halted a Shuttle launch countdown, and only the third time in the history of the program. In 1984, STS-41D was scrubbed at T -4 seconds when the orbiter General Purpose Computer detected an anomaly in a main engine, and in 1985, STS-51F was halted at T -3 seconds due to a main engine malfunction that caused shutdown of all three engines. Columbia had been scheduled to lift off from Launch Pad 39B is the Space Shuttle Discovery, undergoing preparations for lift off on Mission STS-56.

Heat transfer and pressure measurements for the SSME fuel-side turbopump

NASA Technical Reports Server (NTRS)

Dunn, Michael G.

1990-01-01

A measurement program is currently underway at the Calspan-UB Research Center (CUBRC) which utilizes the Rocketdyne two-state fuel-side turbine with the engine geometric configuration reproduced. This is a full two-state turbine for which the vane rows and the blades are the engine hardware currently used on the Space Shuttle turbopump. A status report is provided for the experimental program and a description of the instrumentation and the measurements to be performed. The specific items that will be illustrated and described are as follows: (1) the gas flow path, (2) the heat-flux instrumentation, (3) the surface-pressure instrumentation, (4) the experimental conditions for which data will be obtained, and (5) the specific measurements that will be performed.

Studies and analyses of the space shuttle main engine. Failure information propagation model data base and software

NASA Technical Reports Server (NTRS)

Tischer, A. E.

1987-01-01

The failure information propagation model (FIPM) data base was developed to store and manipulate the large amount of information anticipated for the various Space Shuttle Main Engine (SSME) FIPMs. The organization and structure of the FIPM data base is described, including a summary of the data fields and key attributes associated with each FIPM data file. The menu-driven software developed to facilitate and control the entry, modification, and listing of data base records is also discussed. The transfer of the FIPM data base and software to the NASA Marshall Space Flight Center is described. Complete listings of all of the data base definition commands and software procedures are included in the appendixes.

The application of neural networks to the SSME startup transient

NASA Technical Reports Server (NTRS)

Meyer, Claudia M.; Maul, William A.

1991-01-01

Feedforward neural networks were used to model three parameters during the Space Shuttle Main Engine startup transient. The three parameters were the main combustion chamber pressure, a controlled parameter, the high pressure oxidizer turbine discharge temperature, a redlined parameter, and the high pressure fuel pump discharge pressure, a failure-indicating performance parameter. Network inputs consisted of time windows of data from engine measurements that correlated highly to the modeled parameter. A standard backpropagation algorithm was used to train the feedforward networks on two nominal firings. Each trained network was validated with four additional nominal firings. For all three parameters, the neural networks were able to accurately predict the data in the validation sets as well as the training set.

STS-47 Pilot Brown on OV-105's flight deck ten minutes after SSME cutoff

NASA Image and Video Library

1992-09-12

STS047-28-002 (20 Sept. 1992) --- Astronaut Curtis L. Brown, Jr., STS-47 pilot, is photographed at the Space Shuttle Endeavour's pilot station about ten minutes after main engine cutoff on launch day of the eight-day Spacelab-J mission. Wearing the partial-pressure launch and entry suit, Brown shared the forward cabin with astronaut Robert L. Gibson (out of frame at left), mission commander. Endeavour was beginning its second mission in space, this one devoted to research supporting the Spacelab-J mission.

STS-56 Discovery, OV-103, lifts off from KSC LC Pad 39B into darkness

NASA Technical Reports Server (NTRS)

1993-01-01

STS-56 Discovery, Orbiter Vehicle (OV) 103, lifts off from Kennedy Space Center (KSC) Launch Complex (LC) Pad 39B into the early morning darkness at 1:29 am (Eastern Daylight Time (EDT)). OV-103, atop its external tank (ET) and flanked by solid rocket boosters (SRBs), rises above the mobile launcher platform. Exhaust plumes trail from the SRBs. The glow of the SRB / space shuttle main engine (SSME) firings illuminate the fixed service structure (FSS) tower. Trees are silhouetted against the launch fireworks in the foreground.

Space Shuttle main engine powerhead structural modeling, stress and fatigue life analysis. Volume 3: Stress summay of blades and nozzles at FPL and 115 percent RPL loads. SSME HPFTP and HPOTP blades and nozzles

NASA Technical Reports Server (NTRS)

Hammett, J. C.; Hayes, C. H.; Price, J. M.; Robinson, J. K.; Teal, G. A.; Thomson, J. M.; Tilley, D. M.; Welch, C. T.

1983-01-01

Gasdynamic environments applied to the turbine blades and nozzles of the HPFTP and HPOTP were analyzed. Centrifugal loads were applied to blades to account for the pump rotation of FPL and 115 percent RPL. The computer models used in the blade analysis with results presented in the form of temperature and stress contour plots are described. Similar information is given for the nozzles.

3D rocket combustor acoustics model

NASA Technical Reports Server (NTRS)

Priem, Richard J.; Breisacher, Kevin J.

1992-01-01

The theory and procedures for determining the characteristics of pressure oscillations in rocket engines with prescribed burning rate oscillations are presented. Analyses including radial and hub baffles and absorbers can be performed in one, two, or three dimensions. Pressure and velocity oscillations calculated using this procedure are presented for the SSME to show the influence of baffles and absorbers on the burning rate oscillations required to achieve neutral stability. Comparisons are made between the results obtained utilizing 1D, 2D, and 3D assumption with regards to capturing the physical phenomena of interest and computational requirements.

SSME 3-D Turnaround Duct flow analysis - CFD predictions

NASA Technical Reports Server (NTRS)

Brankovic, Andreja; Stowers, Steven T.; Mcconnaughey, Paul

1988-01-01

CFD analysis is presently employed to obtain an improved flowfield for an individual flowpath in the case of the Space Shuttle Main Engine's High Pressure Fuel Turbopump Turn-Around Duct (TAD), which conducts the flow exiting from the gas turbines into the fuel bowl. It is demonstrated that the application of CFD to TAD flow analysis, giving attention to the duct's configuration and to the number, shape, and alignment of the diffuser struts, can enhance understanding of flow physics and result in improved duct design and performance.

STS-73 Space Shuttle Mission Report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1995-01-01

The STS-73 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the seventy-second flight of the Space Shuttle Program, the forty-seventh flight since the return-to-flight, and the eighteenth flight of the Orbiter Columbia (OV-102). STS-73 was also the first flight of OV-102 following the vehicle's return from the Orbiter Maintenance Down Period (OMDP). In addition to the Orbiter, the flight vehicle consisted of an ET that was designated ET-73; three SSME's that were designated as serial numbers 2037 (Block 1), 2031 (PH-1), and 2038 (Block 1) in positions 1, 2, and 3, respectively; and two SRB's that were designated BI-075. The RSRM's, designated RSRM-50, were installed in each SRB and the individual RSRM's were designated as 36OL050A for the left SRB, and 36OW050B for the right SRB. The primary objective of this flight was to successfully perform the planned operations of the United States Microgravity Laboratory (USML)-2 payload.

An Investigation of State-Space Model Fidelity for SSME Data

NASA Technical Reports Server (NTRS)

Martin, Rodney Alexander

2008-01-01

In previous studies, a variety of unsupervised anomaly detection techniques for anomaly detection were applied to SSME (Space Shuttle Main Engine) data. The observed results indicated that the identification of certain anomalies were specific to the algorithmic method under consideration. This is the reason why one of the follow-on goals of these previous investigations was to build an architecture to support the best capabilities of all algorithms. We appeal to that goal here by investigating a cascade, serial architecture for the best performing and most suitable candidates from previous studies. As a precursor to a formal ROC (Receiver Operating Characteristic) curve analysis for validation of resulting anomaly detection algorithms, our primary focus here is to investigate the model fidelity as measured by variants of the AIC (Akaike Information Criterion) for state-space based models. We show that placing constraints on a state-space model during or after the training of the model introduces a modest level of suboptimality. Furthermore, we compare the fidelity of all candidate models including those embodying the cascade, serial architecture. We make recommendations on the most suitable candidates for application to subsequent anomaly detection studies as measured by AIC-based criteria.

Heat transfer and pressure measurements and comparison with prediction for the SSME two-stage turbine

NASA Technical Reports Server (NTRS)

Dunn, M. G.; Kim, J.

1992-01-01

Time averaged Stanton number and surface pressure distributions are reported for the first stage vane row, the first stage blade row, and the second stage vane row of the Rocketdyne Space Shuttle Main Engine (SSME) two-stage fuel-side turbine. Unsteady pressure envelope measurements for the first blade are also reported. These measurements were made at 10 percent, 50 percent, and 90 percent span on both the pressure and suction surfaces of the first stage components. Additional Stanton number measurements were made on the first stage blade platform, blade tip, and shroud, and at 50 percent span on the second vane. A shock tube was used as a short duration source of heated and pressurized air to which the turbine was subjected. Platinum thin film heat flux gages were used to obtain the heat flux measurements, while miniature silicon diaphragm flush-mounted pressure transducers were used to obtain the pressure measurements. The first stage vane Stanton number distributions are compared with predictions obtained using a version of STAN5 and quasi-3D Navier-Stokes solution. This same quasi-3D N-S code was also used to obtain predictions for the first blade and the second vane.

Simulation of water vapor condensation on LOX droplet surface using liquid nitrogen

NASA Technical Reports Server (NTRS)

Powell, Eugene A.

1988-01-01

The formation of ice or water layers on liquid oxygen (LOX) droplets in the Space Shuttle Main Engine (SSME) environment was investigated. Formulation of such ice/water layers is indicated by phase-equilibrium considerations under conditions of high partial pressure of water vapor (steam) and low LOX droplet temperature prevailing in the SSME preburner or main chamber. An experimental investigation was begun using liquid nitrogen as a LOX simulant. A monodisperse liquid nitrogen droplet generator was developed which uses an acoustic driver to force the stream of liquid emerging from a capillary tube to break up into a stream of regularly space uniformly sized spherical droplets. The atmospheric pressure liquid nitrogen in the droplet generator reservoir was cooled below its boiling point to prevent two phase flow from occurring in the capillary tube. An existing steam chamber was modified for injection of liquid nitrogen droplets into atmospheric pressure superheated steam. The droplets were imaged using a stroboscopic video system and a laser shadowgraphy system. Several tests were conducted in which liquid nitrogen droplets were injected into the steam chamber. Under conditions of periodic droplet formation, images of 600 micron diameter liquid nitrogen droplets were obtained with the stroboscopic video systems.

Bearing optimization for SSME HPOTP application

NASA Technical Reports Server (NTRS)

Armstrong, Elizabeth S.; Coe, Harold H.

1988-01-01

The space shuttle main engine (SSME) high-pressure oxygen turbopumps (HPOTP) have not experienced the service life required of them. To improve the life of the existing turbopump bearings, modifications to the bearings that could be retrofitted into the present bearing cavity are being investigated. Several bearing parameters were optimized using the computer program SHABERTH, which performs a thermomechanical simulation of a load support system. The computer analysis showed that improved bearing performance is feasible if low friction coefficients can be attained. Bearing geometries were optimized considering heat generation, equilibrium temperatures, and relative life. Two sets of curvatures were selected from the optimization: an inner-raceway curvature of 0.54, an outer-raceway curvature of 0.52, and an inner-raceway curvature of 0.55, an outer-raceway curvature of 0.53. A contact angle of 16 deg was also selected. Thermal gradients through the bearings were found to be lower with liquid lubrication than with solid film lubrication. As the coolant flowrate through the bearing increased, the ball temperature decreased but at a continuously decreasing rate. The optimum flowrate was approximately 4 kg/s. The analytical modeling used to determine these feasible modifications to improve bearing performance is described.

Orbit transfer rocket engine technology program. Phase 2: Advanced engine study

NASA Technical Reports Server (NTRS)

Erickson, C.; Martinez, A.; Hines, B.

1987-01-01

In Phase 2 of the Advanced Engine Study, the Failure Modes and Effects Analysis (FMEA) maintenance-driven engine design, preliminary maintenance plan, and concept for space operable disconnects generated in Phase 1 were further developed. Based on the results of the vehicle contractors Orbit Transfer Vehicle (OTV) Concept Definition and System Analysis Phase A studies, minor revisions to the engine design were made. Additional refinements in the engine design were identified through further engine concept studies. These included an updated engine balance incorporating experimental heat transfer data from the Enhanced Heat Load Thrust Chamber Study and a Rao optimum nozzle contour. The preliminary maintenance plan of Phase 1 was further developed through additional studies. These included a compilation of critical component lives and life limiters and a review of the Space Shuttle Main Engine (SSME) operations and maintenance manual in order to begin outlining the overall maintenance procedures for the Orbit Transfer Vehicle Engine and identifying technology requirements for streamlining space-based operations. Phase 2 efforts also provided further definition to the advanced fluid coupling devices including the selection and preliminary design of a preferred concept and a preliminary test plan for its further development.

Investigation of the feasibility of optical diagnostic measurements at the exit of the SSME

NASA Technical Reports Server (NTRS)

Shirley, John A.; Boedeker, Laurence R.

1993-01-01

Under Contract NAS8-36861 sponsored by NASA Marshall Space Flight Center, the United Technologies Research Center is conducting an investigation of the feasibility of remote optical diagnostics to measure temperature, species concentration and velocity at the exit of the Space Shuttle Main Engine (SSME). This is a two phase study consisting of a conceptual design phase followed by a laboratory experimental investigation. The first task of the conceptual design studies is to screen and evaluate the techniques which can be used for the measurements. The second task is to select the most promising technique or techniques, if as expected, more than one type of measurement must be used to measure all the flow variables of interest. The third task is to examine in detail analytically the capabilities and limitations of the selected technique(s). The results of this study are described in the section of this report entitled Conceptual Design Investigations. The conceptual design studies identified spontaneous Raman scattering and photodissociative flow-tagging for measurements respectively of gas temperature and major species concentration and for velocity. These techniques and others that were considered are described in the section describing the conceptual design. The objective of the second phase of investigations was to investigate experimentally the techniques identified in the first phase. The first task of the experimental feasibility study is to design and assemble laboratory scale experimental apparatus to evaluate the best approaches for SSME exit optical diagnostics for temperature, species concentrations and velocity, as selected in the Phase I conceptual design study. The second task is to evaluate performance, investigate limitations, and establish actual diagnostic capabilities, accuracies and precision for the selected optical systems. The third task is to evaluate design requirements and system trade-offs of conceptual instruments. Spontaneous Raman scattering excited by a KrF excimer laser pulse was investigated for SSME exit plane temperature and major species concentration measurements. The relative concentrations of molecular hydrogen and water vapor would be determined by measuring the integrated Q-branch scattering signals through narrow bandpass filters in front of photomultipliers. The temperature would be determined by comparing the signal from a single hydrogen rotational Raman line to the total hydrogen Q-branch signal. The rotational Raman line would be isolated by a monochromator and detected with a PMT.

Evaluation of advanced propulsion options for the next manned transportation system: Propulsion evolution study

NASA Technical Reports Server (NTRS)

Spears, L. T.; Kramer, R. D.

1990-01-01

The objectives were to examine launch vehicle applications and propulsion requirements for potential future manned space transportation systems and to support planning toward the evolution of Space Shuttle Main Engine (SSME) and Space Transportation Main Engine (STME) engines beyond their current or initial launch vehicle applications. As a basis for examinations of potential future manned launch vehicle applications, we used three classes of manned space transportation concepts currently under study: Space Transportation System Evolution, Personal Launch System (PLS), and Advanced Manned Launch System (AMLS). Tasks included studies of launch vehicle applications and requirements for hydrogen-oxygen rocket engines; the development of suggestions for STME engine evolution beyond the mid-1990's; the development of suggestions for STME evolution beyond the Advanced Launch System (ALS) application; the study of booster propulsion options, including LOX-Hydrocarbon options; the analysis of the prospects and requirements for utilization of a single engine configuration over the full range of vehicle applications, including manned vehicles plus ALS and Shuttle C; and a brief review of on-going and planned LOX-Hydrogen propulsion technology activities.

Marshall Space Flight Center CFD overview

NASA Technical Reports Server (NTRS)

Schutzenhofer, Luke A.

1989-01-01

Computational Fluid Dynamics (CFD) activities at Marshall Space Flight Center (MSFC) have been focused on hardware specific and research applications with strong emphasis upon benchmark validation. The purpose here is to provide insight into the MSFC CFD related goals, objectives, current hardware related CFD activities, propulsion CFD research efforts and validation program, future near-term CFD hardware related programs, and CFD expectations. The current hardware programs where CFD has been successfully applied are the Space Shuttle Main Engines (SSME), Alternate Turbopump Development (ATD), and Aeroassist Flight Experiment (AFE). For the future near-term CFD hardware related activities, plans are being developed that address the implementation of CFD into the early design stages of the Space Transportation Main Engine (STME), Space Transportation Booster Engine (STBE), and the Environmental Control and Life Support System (ECLSS) for the Space Station. Finally, CFD expectations in the design environment will be delineated.

Planning for Plume Diagnostics for Ground Testing of J-2X Engines at the SSC

NASA Technical Reports Server (NTRS)

SaintCyr, William W.; Tejwani, Gopal D.; McVay, Gregory P.; Langford, Lester A.; SaintCyr, William W.

2010-01-01

John C. Stennis Space Center (SSC) is the premier test facility for liquid rocket engine development and certification for the National Aeronautics and Space Administration (NASA). Therefore, it is no surprise that the SSC will play the most prominent role in the engine development testing and certification for the J-2X engine. The Pratt & Whitney Rocketdyne J-2X engine has been selected by the Constellation Program to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage in NASA s strategy of risk mitigation for hardware development by building on the Apollo program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. Accordingly, J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development and testing efforts. In order to leverage SSC s successful and innovative expertise in the plume diagnostics for the space shuttle main engine (SSME) health monitoring,1-10 this paper will present a blueprint for plume diagnostics for various proposed ground testing activities for J-2X at SSC. Complete description of the SSC s test facilities, supporting infrastructure, and test facilities is available in Ref. 11. The A-1 Test Stand is currently being prepared for testing the J-2X engine at sea level conditions. The A-2 Test Stand is currently being used for testing the SSME and may also be used for testing the J-2X engine at sea level conditions in the future. Very recently, ground-breaking ceremony for the new A-3 rocket engine test stand took place at SSC on August 23, 2007. A-3 is the first large - scale test stand to be built at the SSC since the A and B stands were constructed in the 1960s. The A-3 Test Stand will be used for testing J-2X engines under vacuum conditions simulating high altitude operation at approximately 30,480 m (100,000 ft). To achieve the simulated altitude environment, chemical steam generators using isopropyl alcohol, LOX, and RELEASED - Printed documents may be obsolete; validate prior to use. water would run for the duration of the test and would generate approximately 2096 Kg/s of steam to reduce pressure in the test cell and downstream of the engine. The testing at the A-3 Test Stand is projected to begin in late 2010, meanwhile the J-2X component testing on A-1 is scheduled to begin later this year.

Demonstration of the Application of Composite Load Spectra (CLS) and Probabilistic Structural Analysis (PSAM) Codes to SSME Heat Exchanger Turnaround Vane

NASA Technical Reports Server (NTRS)

Rajagopal, Kadambi R.; DebChaudhury, Amitabha; Orient, George

2000-01-01

This report describes a probabilistic structural analysis performed to determine the probabilistic structural response under fluctuating random pressure loads for the Space Shuttle Main Engine (SSME) turnaround vane. It uses a newly developed frequency and distance dependent correlation model that has features to model the decay phenomena along the flow and across the flow with the capability to introduce a phase delay. The analytical results are compared using two computer codes SAFER (Spectral Analysis of Finite Element Responses) and NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) and with experimentally observed strain gage data. The computer code NESSUS with an interface to a sub set of Composite Load Spectra (CLS) code is used for the probabilistic analysis. A Fatigue code was used to calculate fatigue damage due to the random pressure excitation. The random variables modeled include engine system primitive variables that influence the operating conditions, convection velocity coefficient, stress concentration factor, structural damping, and thickness of the inner and outer vanes. The need for an appropriate correlation model in addition to magnitude of the PSD is emphasized. The study demonstrates that correlation characteristics even under random pressure loads are capable of causing resonance like effects for some modes. The study identifies the important variables that contribute to structural alternate stress response and drive the fatigue damage for the new design. Since the alternate stress for the new redesign is less than the endurance limit for the material, the damage due high cycle fatigue is negligible.

Tripropellant engine study

NASA Technical Reports Server (NTRS)

Wheeler, D. B.

1977-01-01

Work conducted was devoted to three main tasks. Thermochemical equilibrium performance data were assembled to establish the expected performance calculations of the mode 1 engine propellant combinations and thermodynamic and transport data for the products of combustion. Turbine drive gas characteristics were also established. Thrust chamber and nozzle cooling studies were devoted to the evaluation of H2, C3H8, CH4, and RP-1 as coolants in the existing SSME cooling circuit geometry. It was found that all these candidate coolants are feasible without limiting the desired operating conditions with the exception of RP-1, which would limit the maximum P(c) to 2000 psia. RP-1 could be used, however, to cool the nozzle only without imposing the chamber pressure limit. A total of 15 candidate engine system cycles were selected and a preliminary engine system balance was conducted for 12 of these systems to establish component operating flowrates, pressures and temperatures. It was found that the staged combustion cycles employing fuel rich LOX/hydrocarbon turbine drive gases are power limited.

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.

Definition of Forces on Turbomachinery Rotors. Task B Report: Dynamic Analysis of Rotors

NASA Technical Reports Server (NTRS)

Childs, D. W.

1983-01-01

The rotordynamic characteristics of turbomachinery are known to depend on the forces developed due to relative motion between the rotor and the housing. For example, the critical speed locations generally depend on the bearing stiffnesses, seal dampling influences rotor stability and bearing reaction amplitudes near critical speeds, etc. A systematic examination of the influence of changes in the forces acting on rotors is studied. More specifically, the sensitivity of the rotordynamic characteristics to changes in rotor forces is analyzed. Rotordynamic characteristics of the HPOTP (High Pressure Oxygen Turbopump) and HPFTP (High Pressure Fuel Turbopump) of the SSME (Space Shuttle Main Engine) are investigated. Because of their markedly different rotordynamic characteristics, these units are considered to be representative of a range of possible future liquid rocket engine turbomachinery.

Evaluation and Improvement of Liquid Propellant Rocket Chugging Analysis Techniques. Part 2: a Study of Low Frequency Combustion Instability in Rocket Engine Preburners Using a Heterogeneous Stirred Tank Reactor Model. Final Report M.S. Thesis - Aug. 1987

NASA Technical Reports Server (NTRS)

Bartrand, Timothy A.

1988-01-01

During the shutdown of the space shuttle main engine, oxygen flow is shut off from the fuel preburner and helium is used to push the residual oxygen into the combustion chamber. During this process a low frequency combustion instability, or chug, occurs. This chug has resulted in damage to the engine's augmented spark igniter due to backflow of the contents of the preburner combustion chamber into the oxidizer feed system. To determine possible causes and fixes for the chug, the fuel preburner was modeled as a heterogeneous stirred tank combustion chamber, a variable mass flow rate oxidizer feed system, a constant mass flow rate fuel feed system and an exit turbine. Within the combustion chamber gases were assumed perfectly mixed. To account for liquid in the combustion chamber, a uniform droplet distribution was assumed to exist in the chamber, with mean droplet diameter determined from an empirical relation. A computer program was written to integrate the resulting differential equations. Because chamber contents were assumed perfectly mixed, the fuel preburner model erroneously predicted that combustion would not take place during shutdown. The combustion rate model was modified to assume that all liquid oxygen that vaporized instantaneously combusted with fuel. Using this combustion model, the effect of engine parameters on chamber pressure oscillations during the SSME shutdown was calculated.

STS-45 Atlantis, OV-104, lifts off from KSC Launch Complex (LC) Pad

NASA Image and Video Library

1992-03-24

STS-45 Atlantis, Orbiter Vehicle (OV) 104, lifts off from a Kennedy Space Center (KSC) Launch Complex (LC) Pad at 8:13:40:048 am (Eastern Standard Time (EST)). Exhaust billows out the solid rocket boosters (SRBs) as OV-104 atop its external tank (ET) soars above the mobile launcher platform and is nearly clear of the fixed service structure (FSS) tower. The diamond shock effect produced by the space shuttle main engines (SSMEs) is visible. The glow of the SRB/SSME firings is reflected in a nearby waterway. An exhaust cloud covers the launch pad area.

Development, qualification, and delivery of a hydrogen burnoff igniter

NASA Technical Reports Server (NTRS)

Ray, D.

1981-01-01

The hydrogen burnoff igniter, a pyrotechnic device used to burn off excess hydrogen gas near the Space Shuttle Main Engine (SSME) nozzle, was designed, fabricated, and qualified. Characteristics of the burnoff igniter include a function time of 8 + or - 2 seconds, a minimum three foot flame length at maximum output, and hot particles projected 15 feet when fired directly into or perpendicular to a 34.5 knot wind. The three foot flame length was considered to be of questionable importance, since the hot particles are the media for igniting the hydrogen. Flame temperature is greater than 1500 F.

Constitutive and damage material modeling in a high pressure hydrogen environment

NASA Technical Reports Server (NTRS)

Russell, D. A.; Fritzemeier, L. G.

1991-01-01

Numerous components in reusable space propulsion systems such as the SSME are exposed to high pressure gaseous hydrogen environments. Flow areas and passages in the fuel turbopump, fuel and oxidizer preburners, main combustion chamber, and injector assembly contain high pressure hydrogen either high in purity or as hydrogen rich steam. Accurate constitutive and damage material models applicable to high pressure hydrogen environments are therefore needed for engine design and analysis. Existing constitutive and cyclic crack initiation models were evaluated only for conditions of oxidizing environments. The main objective is to evaluate these models for applicability to high pressure hydrogen environments.

Signal analysis techniques for incipient failure detection in turbomachinery

NASA Technical Reports Server (NTRS)

Coffin, T.

1985-01-01

Signal analysis techniques for the detection and classification of incipient mechanical failures in turbomachinery were developed, implemented and evaluated. Signal analysis techniques available to describe dynamic measurement characteristics are reviewed. Time domain and spectral methods are described, and statistical classification in terms of moments is discussed. Several of these waveform analysis techniques were implemented on a computer and applied to dynamic signals. A laboratory evaluation of the methods with respect to signal detection capability is described. Plans for further technique evaluation and data base development to characterize turbopump incipient failure modes from Space Shuttle main engine (SSME) hot firing measurements are outlined.

The 3D rocket combustor acoustics model

NASA Technical Reports Server (NTRS)

Priem, Richard J.; Breisacher, Kevin J.

1992-01-01

The theory and procedures for determining the characteristics of pressure oscillations in rocket engines with prescribed burning rate oscillations are presented. Analyses including radial and hub baffles and absorbers can be performed in one, two, and three dimensions. Pressure and velocity oscillations calculated using this procedure are presented for the SSME to show the influence of baffles and absorbers on the burning rate oscillations required to achieve neutral stability. Comparisons are made between the results obtained utilizing 1-D, 2-D, and 3-D assumptions with regards to capturing the physical phenomena of interest and computational requirements.

A steam inerting system for hydrogen disposal for the Vandenberg Shuttle

NASA Technical Reports Server (NTRS)

Belknap, Stuart B.

1988-01-01

A two-year feasibility and test program to solve the problem of unburned confined hydrogen at the Vandenberg Space Launch Complex Six (SLC-6) during Space Shuttle Main Engine (SSME) firings is discussed. A novel steam inerting design was selected for development. Available sound suppression water is superheated to flash to steam at the duct entrance. Testing, analysis, and design during 1987 showed that the steam inerting system (SIS) solves the problem and meets other flight-critical system requirements. The SIS design is complete and available for installation at SLC-6 to support shuttle or derivative vehicles.

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.

Comparison Between Predicted and Experimentally Measured Flow Fields at the Exit of the SSME HPFTP Impeller

NASA Technical Reports Server (NTRS)

Bache, George

1993-01-01

Validation of CFD codes is a critical first step in the process of developing CFD design capability. The MSFC Pump Technology Team has recognized the importance of validation and has thus funded several experimental programs designed to obtain CFD quality validation data. The first data set to become available is for the SSME High Pressure Fuel Turbopump Impeller. LDV Data was taken at the impeller inlet (to obtain a reliable inlet boundary condition) and three radial positions at the impeller discharge. Our CFD code, TASCflow, is used within the Propulsion and Commercial Pump industry as a tool for pump design. The objective of this work, therefore, is to further validate TASCflow for application in pump design. TASCflow was used to predict flow at the impeller discharge for flowrates of 80, 100 and 115 percent of design flow. Comparison to data has been made with encouraging results.

Next-Generation RS-25 Engines for the NASA Space Launch System

NASA Technical Reports Server (NTRS)

Ballard, Richard O.

2017-01-01

The utilization of heritage RS-25 engine, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway at NASA and the RS-25 engine provider, Aerojet Rocketdyne, to improve system affordability and eliminate obsolescence concerns. This paper describes how the achievement of these key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Fretting Stresses in Single Crystal Superalloy Turbine Blade Attachments

NASA Technical Reports Server (NTRS)

Arakere, Nagaraj K.; Swanson, Gregory

2000-01-01

Single crystal nickel base superalloy turbine blades are being utilized in rocket engine turbopumps and turbine engines because of their superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys. Currently the most widely used single crystal nickel base turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. High Cycle Fatigue (HCF) induced failures in aircraft gas turbine and rocket engine turbopump blades is a pervasive problem. Blade attachment regions are prone to fretting fatigue failures. Single crystal nickel base superalloy turbine blades are especially prone to fretting damage because the subsurface shear stresses induced by fretting action at the attachment regions can result in crystallographic initiation and crack growth along octahedral planes. Furthermore, crystallographic crack growth on octahedral planes under fretting induced mixed mode loading can be an order of magnitude faster than under pure mode I loading. This paper presents contact stress evaluation in the attachment region for single crystal turbine blades used in the NASA alternate Advanced High Pressure Fuel Turbo Pump (HPFTP/AT) for the Space Shuttle Main Engine (SSME). Single crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant factor in the overall analysis. Blades and the attachment region are modeled using a large-scale 3D finite element (FE) model capable of accounting for contact friction, material orthotrophy, and variation in primary and secondary crystal orientation. Contact stress analysis in the blade attachment regions is presented as a function of coefficient of friction and primary and secondary crystal orientation, Stress results are used to discuss fretting fatigue failure analysis of SSME blades. Attachment stresses are seen to reach peak values at locations where fretting cracks have been observed. Fretting stresses at the attachment region are seen to vary significantly as a function of crystal orientation. Attempts to adapt techniques used for estimating fatigue life in the airfoil region, for life calculations in the attachment region, are presented. An effective model for predicting crystallographic crack initiation under mixed mode loading is required for life prediction under fretting action.

STS-67 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1995-01-01

The STS-67 Space Shuttle Program Mission Report provides the results of the orbiter vehicle performance evaluation during this sixty-eighth flight of the Shuttle Program, the forty-third flight since the return to flight, and the eighth flight of the Orbiter vehicle Endeavour (OV-105). In addition, the report summarizes the payload activities and the performance of the External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle Main Engines (SSME). The serial numbers of the other elements of the flight vehicle were ET-69 for the ET; 2012, 2033, and 2031 for SSME's 1, 2, and 3, respectively; and Bl-071 for the SRB's. The left-hand RSRM was designated 360W043A, and the right-hand RSRM was designated 360L043B. The primary objective of this flight was to successfully perform the operations of the ultraviolet astronomy (ASTRO-2) payload. Secondary objectives of this flight were to complete the operations of the Protein Crystal Growth - Thermal Enclosure System (PCG-TES), the Protein Crystal Growth - Single Locker Thermal Enclosure System (PCG-STES), the Commercial Materials Dispersion Apparatus ITA Experiments (CMIX), the Shuttle Amateur Radio Experiment-2 (SAREX-2), the Middeck Active Control Experiment (MACE), and two Get-Away Special (GAS) payloads.

Dynamic analysis of nonlinear rotor-housing systems

NASA Technical Reports Server (NTRS)

Noah, Sherif T.

1988-01-01

Nonlinear analysis methods are developed which will enable the reliable prediction of the dynamic behavior of the space shuttle main engine (SSME) turbopumps in the presence of bearing clearances and other local nonlinearities. A computationally efficient convolution method, based on discretized Duhamel and transition matrix integral formulations, is developed for the transient analysis. In the formulation, the coupling forces due to the nonlinearities are treated as external forces acting on the coupled subsystems. Iteration is utilized to determine their magnitudes at each time increment. The method is applied to a nonlinear generic model of the high pressure oxygen turbopump (HPOTP). As compared to the fourth order Runge-Kutta numerical integration methods, the convolution approach proved to be more accurate and more highly efficient. For determining the nonlinear, steady-state periodic responses, an incremental harmonic balance method was also developed. The method was successfully used to determine dominantly harmonic and subharmonic responses fo the HPOTP generic model with bearing clearances. A reduction method similar to the impedance formulation utilized with linear systems is used to reduce the housing-rotor models to their coordinates at the bearing clearances. Recommendations are included for further development of the method, for extending the analysis to aperiodic and chaotic regimes and for conducting critical parameteric studies of the nonlinear response of the current SSME turbopumps.

STS-65 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1994-01-01

The STS-65 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the sixty-third flight of the Space Shuttle Program and the seventeenth flight of the Orbiter vehicle Columbia (OV-102). In addition to the Orbits the flight vehicle consisted of an ET that was designated ET-64; three SSME's that were designated as serial numbers 2019, 2030, and 2017 in positions 1, 2, and 3, respectively; and two SRB's that were designated Bl-066. The RSRM's that were installed in each SRB were designated as 360P039A for the left SRB, and 360W039 for the right SRB. The primary objective of this flight was to complete the operation of the second International Microgravity Laboratory (IML-2). The secondary objectives of this flight were to complete the operations of the Commercial Protein Crystal Growth (CPCG), Orbital Acceleration Research Experiment (OARE), and the Shuttle Amateur Radio Experiment (SAREX) II payloads. Additional secondary objectives were to meet the requirements of the Air Force Maui Optical Site (AMOS) and the Military Application Ship Tracks (MAST) payloads, which were manifested as payloads of opportunity.

Viscous flow computations for elliptical two-duct version of the SSME hot gas manifold

NASA Technical Reports Server (NTRS)

Roger, R. P.

1986-01-01

The objective of the effort was to numerically simulate viscous subsonic flow in a proposed elliptical two-duct version of the fuel side Hot Gas Manifold (HGM) for the Space Shuttle Main Engine (SSME). The numerical results were to complement both water flow and air flow experiments in the two-duct geometry performed at NASA-MSFC and Rocketdyne. The three-dimensional character of the HGM consists of two essentially different geometries. The first part of the construction is a concentric shell duct structure which channels the gases from a turbine exit into the second part comprised of two cylindrically shaped transfer ducts. The initial concentric shell portion can be further subdivided into a turnaround section and a bowl section. The turnaround duct (TAD) changes the direction of the mean flow by 180 degress from a smaller radius to a larger radius duct which discharges into the bowl. The cylindrical transfer ducts are attached to the bowl on one side thus providing a plane of symmetry midway between the two. Centerline flow distance from the TAD inlet to the transfer duct exit is approximately two feet. Details of the approach used to numerically simulate laminar or turbulent flow in the HGM geometry are presented. Computational results are presented and discussed.

STS-53 Space Shuttle mission report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1993-01-01

The STS-53 Space Shuttle Program Mission Report provides a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle Main Engine (SSME) subsystems performance during the fifty-second flight of the Space Shuttle Program, and the fifteenth flight of the Orbiter vehicle Discovery (OV-103). In addition to the Orbiter, the flight vehicle consisted of an ET, which was designated as ET-49/LWT-42; three SSME's, which were serial numbers 2024, 2012, and 2017 in positions 1, 2, and 3, respectively; and two SRB's, which were designated BI-055. The lightweight RSRM's that were installed in each SRB were designated 360L028A for the left SRB, and 360L028B for the right SRB. The primary objective of this flight was to successfully deploy the Department of Defense 1 (DOD-1) payload. The secondary objectives of this flight were to perform the operations required by the Glow Experiment/Cryogenic Heat Pipe Experiment Payload (GCP); the Hand-Held, Earth-Oriented, Real-Time, Cooperative, User-Friendly, Location-Targeting and Environmental System (HERCULES); the Space Tissue Loss (STL); the Battlefield Laser Acquisition Sensor Test (BLAST); the Radiation Monitoring Equipment-III (RME-III); the Microcapsules in Space-1 (MIS-1); the Visual Function Tester-2 (VFT-2); the Cosmic Radiation Effects and Activation Monitor (CREAM); the Clouds Logic to Optimize Use of Defense Systems-1A (CLOUDS-1A); the Fluids Acquisition and Resupply Experiment (FARE); and the Orbital Debris Radar Calibration Spheres (ODERACS). In addition to presenting a summary of subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. Listed in the discussion of each anomaly is the officially assigned tracking number as published by each Project Office in their respective Problem Tracking List. All times given in this report are in Greenwich mean time (G.m.t.) as well as mission elapsed time (MET).

STS-53 Space Shuttle mission report

NASA Astrophysics Data System (ADS)

Fricke, Robert W., Jr.

1993-02-01

The STS-53 Space Shuttle Program Mission Report provides a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle Main Engine (SSME) subsystems performance during the fifty-second flight of the Space Shuttle Program, and the fifteenth flight of the Orbiter vehicle Discovery (OV-103). In addition to the Orbiter, the flight vehicle consisted of an ET, which was designated as ET-49/LWT-42; three SSME's, which were serial numbers 2024, 2012, and 2017 in positions 1, 2, and 3, respectively; and two SRB's, which were designated BI-055. The lightweight RSRM's that were installed in each SRB were designated 360L028A for the left SRB, and 360L028B for the right SRB. The primary objective of this flight was to successfully deploy the Department of Defense 1 (DOD-1) payload. The secondary objectives of this flight were to perform the operations required by the Glow Experiment/Cryogenic Heat Pipe Experiment Payload (GCP); the Hand-Held, Earth-Oriented, Real-Time, Cooperative, User-Friendly, Location-Targeting and Environmental System (HERCULES); the Space Tissue Loss (STL); the Battlefield Laser Acquisition Sensor Test (BLAST); the Radiation Monitoring Equipment-III (RME-III); the Microcapsules in Space-1 (MIS-1); the Visual Function Tester-2 (VFT-2); the Cosmic Radiation Effects and Activation Monitor (CREAM); the Clouds Logic to Optimize Use of Defense Systems-1A (CLOUDS-1A); the Fluids Acquisition and Resupply Experiment (FARE); and the Orbital Debris Radar Calibration Spheres (ODERACS). In addition to presenting a summary of subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. Listed in the discussion of each anomaly is the officially assigned tracking number as published by each Project Office in their respective Problem Tracking List. All times given in this report are in Greenwich mean time (G.m.t.) as well as mission elapsed time (MET).

Vacuum plasma coatings for turbine blades

NASA Technical Reports Server (NTRS)

Holmes, R. R.

1985-01-01

Turbine blades, vacuum plasma spray coated with NiCrAlY, CoCrAlY or NiCrAlY/Cr2O3, were evaluated and rated superior to standard space shuttle main engine (SSME) coated blades. Ratings were based primarily on 25 thermal cycles in the MSFC Burner Rig Tester, cycling between 1700 F (gaseous H2) and -423 F (liquid H2). These tests showed no spalling on blades with improved vacuum plasma coatings, while standard blades spalled. Thermal barrier coatings of ZrO2, while superior to standard coatings, lacked the overall performance desired. Fatigue and tensile specimens, machined from MAR-M-246(Hf) test bars identical to the blades were vacuum plasma spray coated, diffusion bond treated, and tested to qualify the vacuum plasma spray process for flight hardware testing and application. While NiCrAlY/Cr2O3 offers significant improvement over standard coatings in durability and thermal protection, studies continue with an objective to develop coatings offering even greater improvements.

REIMR - A Process for Utilizing Liquid Rocket Propulsion-Oriented 'Lessons Learned' to Mitigate Development Risk in Nuclear Thermal Propulsion

NASA Technical Reports Server (NTRS)

Ballard, RIchard O.

2006-01-01

This paper is a summary overview of a study conducted at the NASA Marshall Space Flight Center (NASA MSFC) during the initial phases of the Space Launch Initiative (SLI) program to evaluate a large number of technical problems associated with the design, development, test, evaluation and operation of several major liquid propellant rocket engine systems (i.e., SSME, Fastrac, J-2, F-1). One of the primary results of this study was the identification of the Fundamental Root Causes that enabled the technical problems to manifest, and practices that can be implemented to prevent them from recurring in future propulsion system development efforts, such as that which is currently envisioned in the field of nuclear thermal propulsion (NTF). This paper will discuss the Fundamental Root Causes, cite some examples of how the technical problems arose from them, and provide a discussion of how they can be mitigated or avoided in the development of an NTP system

Space shuttle propulsion estimation development verification

NASA Technical Reports Server (NTRS)

Rogers, Robert M.

1989-01-01

The application of extended Kalman filtering to estimating the Space Shuttle Propulsion performance, i.e., specific impulse, from flight data in a post-flight processing computer program is detailed. The flight data used include inertial platform acceleration, SRB head pressure, SSME chamber pressure and flow rates, and ground based radar tracking data. The key feature in this application is the model used for the SRB's, which is a nominal or reference quasi-static internal ballistics model normalized to the propellant burn depth. Dynamic states of mass overboard and propellant burn depth are included in the filter model to account for real-time deviations from the reference model used. Aerodynamic, plume, wind and main engine uncertainties are also included for an integrated system model. Assuming uncertainty within the propulsion system model and attempts to estimate its deviations represent a new application of parameter estimation for rocket powered vehicles. Illustrations from the results of applying this estimation approach to several missions show good quality propulsion estimates.

STS-63 Space Shuttle report

NASA Technical Reports Server (NTRS)

Fricke, Robert W., Jr.

1995-01-01

The STS-63 Space Shuttle Program Mission Report summarizes the Payload activities and provides detailed data on the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle Main Engine (SSME) systems performance during this sixty-seventh flight of the Space Shuttle Program, the forty-second since the return to flight, and twentieth flight of the Orbiter vehicle Discovery (OV-103). In addition to the OV-103 Orbiter vehicle, the flight vehicle consisted of an ET that was designated ET-68; three SSME's that were designated 2035, 2109, and 2029 in positions 1, 2, and 3, respectively; and two SRB's that were designated BI-070. The RSRM's that were an integral part of the SRB's were designated 360Q042A for the left SRB and 360L042B for the right SRB. The STS-63 mission was planned as an 8-day duration mission with two contingency days available for weather avoidance or Orbiter contingency operations. The primary objectives of the STS-63 mission were to perform the Mir rendezvous operations, accomplish the Spacehab-3 experiments, and deploy and retrieve the Shuttle Pointed Autonomous Research Tool for Astronomy-204 (SPARTAN-204) payload. The secondary objectives were to perform the Cryogenic Systems Experiment (CSE)/Shuttle Glo-2 Experiment (GLO-2) Payload (CGP)/Orbital Debris Radar Calibration Spheres (ODERACS-2) (CGP/ODERACS-2) payload objectives, the Solid Surface Combustion Experiment (SSCE), and the Air Force Maui Optical Site Calibration Tests (AMOS). The objectives of the Mir rendezvous/flyby were to verify flight techniques, communication and navigation-aid sensor interfaces, and engineering analyses associated with Shuttle/Mir proximity operations in preparation for the STS-71 docking mission.

CLV First Stage Design, Development, Test and Evaluation

NASA Technical Reports Server (NTRS)

Burt, Richard K.; Brasfield, F.

2006-01-01

The Crew Launch Vehicle (CLV) is an integral part of NASA's Exploration architecture that will provide crew and cargo access to the International Space Station as well as low earth orbit support for lunar missions. Currently in the system definition phase, the CLV is planned to replace the Space Shuttle for crew transport in the post 2010 time frame. It is comprised of a solid rocket booster first stage derived from the current Space Shuttle SRB, a LOX/hydrogen liquid fueled second stage utilizing a derivative of the Space Shuttle Main Engine (SSME) for propulsion, and a Crew Exploration Vehicle (GEV) composed of Command and Service Modules. This paper deals with current DDT&E planning for the CLV first stage solid rocket booster. Described are the current overall point-of-departure design and booster subsystems, systems engineering approach, and milestone schedule requirements.

Cyclic structural analyses of anisotropic turbine blades for reusable space propulsion systems. [ssme fuel turbopump

NASA Technical Reports Server (NTRS)

Manderscheid, J. M.; Kaufman, A.

1985-01-01

Turbine blades for reusable space propulsion systems are subject to severe thermomechanical loading cycles that result in large inelastic strains and very short lives. These components require the use of anisotropic high-temperature alloys to meet the safety and durability requirements of such systems. To assess the effects on blade life of material anisotropy, cyclic structural analyses are being performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine. The blade alloy is directionally solidified MAR-M 246 alloy. The analyses are based on a typical test stand engine cycle. Stress-strain histories at the airfoil critical location are computed using the MARC nonlinear finite-element computer code. The MARC solutions are compared to cyclic response predictions from a simplified structural analysis procedure developed at the NASA Lewis Research Center.

Analysis of cavitation damage on the Space Shuttle main engine high pressure oxidizer turbopump

NASA Technical Reports Server (NTRS)

Stinebring, D. R.

1985-01-01

The performance of the Space Shuttle Main Engines (SSME) has met or exceeded specifications. However, the durability for selected components has not met the desired lifetime criteria. Thus, the High-Pressure Oxidizer Turbopump (HPOTP) has experienced cavitation erosion problems in a number of locations in the pump. An investigation was conducted, taking into account an analysis of the cavitation damage, the development of a flow model for the pump, and the recommendation of design changes which would increase the life expectancy of the unit. The present paper is concerned with the cavitation damage analysis. A model is presented which relates the heavy damage on the housing and over the inducer blades to unsteady blade surface cavitation. This cavitation occurs on the inducer blades in the wakes downstream of the pump inlet housing vanes.

Computation of Coupled Thermal-Fluid Problems in Distributed Memory Environment

NASA Technical Reports Server (NTRS)

Wei, H.; Shang, H. M.; Chen, Y. S.

2001-01-01

The thermal-fluid coupling problems are very important to aerospace and engineering applications. Instead of analyzing heat transfer and fluid flow separately, this study merged two well-accepted engineering solution methods, SINDA for thermal analysis and FDNS for fluid flow simulation, into a unified multi-disciplinary thermal fluid prediction method. A fully conservative patched grid interface algorithm for arbitrary two-dimensional and three-dimensional geometry has been developed. The state-of-the-art parallel computing concept was used to couple SINDA and FDNS for the communication of boundary conditions through PVM (Parallel Virtual Machine) libraries. Therefore, the thermal analysis performed by SINDA and the fluid flow calculated by FDNS are fully coupled to obtain steady state or transient solutions. The natural convection between two thick-walled eccentric tubes was calculated and the predicted results match the experiment data perfectly. A 3-D rocket engine model and a real 3-D SSME geometry were used to test the current model, and the reasonable temperature field was obtained.

Atmospheric Mining in the Outer Solar System: Outer Planet Orbital Transfer and Lander Analyses

NASA Technical Reports Server (NTRS)

Palaszewski, Bryan

2016-01-01

High energy propellants for human lunar missions are analyzed, focusing on very advanced ozone and atomic hydrogen. One of the most advanced launch vehicle propulsion systems, such as the Space Shuttle Main Engine (SSME), used hydrogen and oxygen and had a delivered specific impulse of 453 seconds. In the early days of the space program, other propellants (or so called metapropellants) were suggested, including atomic hydrogen and liquid ozone. Theoretical and experimental studies of atomic hydrogen and ozone were conducted beginning in the late 1940s. This propellant research may have provided screenwriters with the idea of an atomic hydrogen-ozone rocket engine in the 1950 movie, Rocketship X-M. This paper presents analyses showing that an atomic hydrogen-ozone rocket engine could produce a specific impulse over a wide range of specific impulse values reaching as high as 1,600 seconds. A series of single stage and multistage rocket vehicle analyses were conducted to find the minimum specific impulse needed to conduct high energy round trip lunar missions.

Propulsion Estimates for High Energy Lunar Missions Using Future Propellants

NASA Technical Reports Server (NTRS)

Palaszewski, Bryan A.; Bennett, Gary L.

2016-01-01

High energy propellants for human lunar missions are analyzed, focusing on very advanced ozone and atomic hydrogen. One of the most advanced launch vehicle propulsion systems, such as the Space Shuttle Main Engine (SSME), used hydrogen and oxygen and had a delivered specific impulse of 453 seconds. In the early days of the space program, other propellants (or so called metapropellants) were suggested, including atomic hydrogen and liquid ozone. Theoretical and experimental studies of atomic hydrogen and ozone were conducted beginning in the late 1940s. This propellant research may have provided screenwriters with the idea of an atomic hydrogen-ozone rocket engine in the 1950 movie, Rocketship X-M. This paper presents analyses showing that an atomic hydrogen-ozone rocket engine could produce a specific impulse over a wide range of specific impulse values reaching as high as 1,600 s. A series of single stage and multistage rocket vehicle analyses were conducted to find the minimum specific impulse needed to conduct high energy round trip lunar missions.

Velocimetry with refractive index matching for complex flow configurations, phase 1

NASA Technical Reports Server (NTRS)

Thompson, B. E.; Vafidis, C.; Whitelaw, J. H.

1987-01-01

The feasibility of obtaining detailed velocity field measurements in large Reynolds number flow of the Space Shuttle Main Engine (SSME) main injector bowl was demonstrated using laser velocimetry and the developed refractive-index-matching technique. An experimental system to provide appropriate flow rates and temperature control of refractive-index-matching fluid was designed and tested. Test results are presented to establish the feasibility of obtaining accurate velocity measurements that map the entire field including the flow through the LOX post bundles: sample mean velocity, turbulence intensity, and spectral results are presented. The results indicate that a suitable fluid and control system is feasible for the representation of complex rocket-engine configurations and that measurements of velocity characteristics can be obtained without the optical access restrictions normally associated with laser velocimetry. The refractive-index-matching technique considered needs to be further developed and extended to represent other rocket-engine flows where current methods either cannot measure with adequate accuracy or they fail.

Multiple dopant injection system for small rocket engines

NASA Technical Reports Server (NTRS)

Sakala, G. G.; Raines, N. G.

1992-01-01

The Diagnostics Test Facility (DTF) at NASA's Stennis Space Center (SSC) was designed and built to provide a standard rocket engine exhaust plume for use in the research and development of engine health monitoring instrumentation. A 1000 lb thrust class liquid oxygen (LOX)-gaseous hydrogen (GH2) fueled rocket engine is used as the subscale plume source to simulate the SSME during experimentation and instrument development. The ability of the DTF to provide efficient, and low cost test operations makes it uniquely suited for plume diagnostic experimentation. The most unique feature of the DTF is the Multiple Dopant Injection System (MDIS) that is used to seed the exhaust plume with the desired element or metal alloy. The dopant injection takes place at the fuel injector, yielding a very uniform and homogeneous distribution of the seeding material in the exhaust plume. The MDIS allows during a single test firing of the DTF, the seeding of the exhaust plume with up to three different dopants and also provides distilled water base lines between the dopants. A number of plume diagnostic-related experiments have already utilized the unique capabilities of the DTF.

From Earth to Orbit: An assessment of transportation options

NASA Technical Reports Server (NTRS)

Gavin, Joseph G., Jr.; Blond, Edmund; Brill, Yvonne C.; Budiansky, Bernard; Cooper, Robert S.; Demisch, Wolfgang H.; Hawk, Clark W.; Kerrebrock, Jack L.; Lichtenberg, Byron K.; Mager, Artur

1992-01-01

The report assesses the requirements, benefits, technological feasibility, and roles of Earth-to-Orbit transportation systems and options that could be developed in support of future national space programs. Transportation requirements, including those for Mission-to-Planet Earth, Space Station Freedom assembly and operation, human exploration of space, space science missions, and other major civil space missions are examined. These requirements are compared with existing, planned, and potential launch capabilities, including expendable launch vehicles (ELV's), the Space Shuttle, the National Launch System (NLS), and new launch options. In addition, the report examines propulsion systems in the context of various launch vehicles. These include the Advanced Solid Rocket Motor (ASRM), the Redesigned Solid Rocket Motor (RSRM), the Solid Rocket Motor Upgrade (SRMU), the Space Shuttle Main Engine (SSME), the Space Transportation Main Engine (STME), existing expendable launch vehicle engines, and liquid-oxygen/hydrocarbon engines. Consideration is given to systems that have been proposed to accomplish the national interests in relatively cost effective ways, with the recognition that safety and reliability contribute to cost-effectiveness. Related resources, including technology, propulsion test facilities, and manufacturing capabilities are also discussed.

Investigation of the fuel feed line failures on the Space Shuttle main engine

NASA Technical Reports Server (NTRS)

Larson, E. W.

1980-01-01

The Space Shuttle Main Engine (SSME) development program experienced two similar appearing fuel feed line failures during the shutdown portion of two engine tests. Failure investigations into each incident showed that a few cycles of high-amplitude transient strain occurring during the start and cutoff portions of each test could have either accumulated damage and led to a fatigue failure after 46 tests, or caused rupture in a low-strength weld joint. The cause of the high strain was traced to a period of unsteady flow separation during the start and cutoff of each test coincident with the oblique shock approaching the nozzle exit. Since elimination of the flow separation was impractical, the steps taken to allow engine development and flight preparations to continue were: (1) establish the safe operating life of the nozzle, (2) reinforce all low-strength welds, and (3) eliminate the use of thin-wall fuel feed lines. In parallel, the feed line was redesigned and fabrication was initiated on units to be incorporated into the development program.

Solar power satellite. System definition study. Part 1, volume 5: SPS transportation. Representative system descriptions

NASA Technical Reports Server (NTRS)

1977-01-01

Both LEO transportation (earth to low earth orbit) and GEO transportation (low earth orbit to geosynchronous orbit) segments were addressed. LEO options include both a 2 stage winged space freighter vehicle and a 2 stage ballistic recoverable vehicle. Both incorporate LO(2)/RP-1/LH(2) engines on the booster and standard SSME's on the upper stage. The orbit transfer vehicle options included chemical for geosynchronous satellite assembly and self powered electric propulsion for low earth orbit satellite assembly. An exhaust products analysis was conducted for the earth to LEO vehicle since atmospheric pollution could be a concern.

Towards Rocket Engine Components with Increased Strength and Robust Operating Characteristics

NASA Technical Reports Server (NTRS)

Marcu, Bogdan; Hadid, Ali; Lin, Pei; Balcazar, Daniel; Rai, Man Mohan; Dorney, Daniel J.

2005-01-01

High-energy rotating machines, powering liquid propellant rocket engines, are subject to various sources of high and low cycle fatigue generated by unsteady flow phenomena. Given the tremendous need for reliability in a sustainable space exploration program, a fundamental change in the design methodology for engine components is required for both launch and space based systems. A design optimization system based on neural-networks has been applied and demonstrated in the redesign of the Space Shuttle Main Engine (SSME) Low Pressure Oxidizer Turbo Pump (LPOTP) turbine nozzle. One objective of the redesign effort was to increase airfoil thickness and thus increase its strength while at the same time detuning the vane natural frequency modes from the vortex shedding frequency. The second objective was to reduce the vortex shedding amplitude. The third objective was to maintain this low shedding amplitude even in the presence of large manufacturing tolerances. All of these objectives were achieved without generating any detrimental effects on the downstream flow through the turbine, and without introducing any penalty in performance. The airfoil redesign and preliminary assessment was performed in the Exploration Technology Directorate at NASA ARC. Boeing/Rocketdyne and NASA MSFC independently performed final CFD assessments of the design. Four different CFD codes were used in this process. They include WIL DCA T/CORSAIR (NASA), FLUENT (commercial), TIDAL (Boeing Rocketdyne) and, a new family (AardvarWPhantom) of CFD analysis codes developed at NASA MSFC employing LOX fluid properties and a Generalized Equation Set formulation. Extensive aerodynamic performance analysis and stress analysis carried out at Boeing Rocketdyne and NASA MSFC indicate that the redesign objectives have been fully met. The paper presents the results of the assessment analysis and discusses the future potential of robust optimal design for rocket engine components.

Using Wearable Computers in Shuttle Processing: A Feasibility Study

NASA Technical Reports Server (NTRS)

Centeno, Martha A.; Correa, Daisy; Groh-Hammond, Marcia

2001-01-01

Shuttle processing operations are performed following prescribed instructions compiled in a Work Authorization Document (WAD). Until very recently, WADs were printed so that they could be properly executed, including the buy off of each and every step by the appropriate authorizing agent. However, with the development of EPICs, Maximo, and PeopleSoft applications, some of these documents are now available in electronic format; hence, it is possible for technicians and engineers to access them on line and buy off the steps electronically. To take full advantage of these developments, technicians need access to such documents at the point of job execution. Body wearable computers present an opportunity to develop a WAD delivery system that enables access while preserving technician's mobility, safety levels, and quality of work done. The primary objectives of this project were to determine if body wearable computers are a feasible delivery system for WADs. More specifically, identify and recommend specific brands of body wearable computers readily available on the market. Thus, this effort has field-tested this technology in two areas of shuttle processing, and it has examined the usability of the technology. Results of two field tests and a Human Factors Usability Test are presented. Section 2 provides a description of the body wearable computer technology. Section 3 presents the test at the Space Shuttle Main Engine (SSME) Shop. Section 4 presents the results of the integration test at the Solid Rocket Boosters Assembly and Refurbishing Facility (SRBARF). Section 5 presents the results of the usability test done at the Operations Support Building (OSB).

Modular Rocket Engine Control Software (MRECS)

NASA Technical Reports Server (NTRS)

Tarrant, C.; Crook, J.

1998-01-01

The Modular Rocket Engine Control Software (MRECS) Program is a technology demonstration effort designed to advance the state-of-the-art in launch vehicle propulsion systems. Its emphasis is on developing and demonstrating a modular software architecture for advanced engine control systems that will result in lower software maintenance (operations) costs. It effectively accommodates software requirement changes that occur due to hardware technology upgrades and engine development testing. Ground rules directed by MSFC were to optimize modularity and implement the software in the Ada programming language. MRECS system software and the software development environment utilize Commercial-Off-the-Shelf (COTS) products. This paper presents the objectives, benefits, and status of the program. The software architecture, design, and development environment are described. MRECS tasks are defined and timing relationships given. Major accomplishments are listed. MRECS offers benefits to a wide variety of advanced technology programs in the areas of modular software architecture, reuse software, and reduced software reverification time related to software changes. MRECS was recently modified to support a Space Shuttle Main Engine (SSME) hot-fire test. Cold Flow and Flight Readiness Testing were completed before the test was cancelled. Currently, the program is focused on supporting NASA MSFC in accomplishing development testing of the Fastrac Engine, part of NASA's Low Cost Technologies (LCT) Program. MRECS will be used for all engine development testing.

Modular Rocket Engine Control Software (MRECS)

NASA Technical Reports Server (NTRS)

Tarrant, Charlie; Crook, Jerry

1997-01-01

The Modular Rocket Engine Control Software (MRECS) Program is a technology demonstration effort designed to advance the state-of-the-art in launch vehicle propulsion systems. Its emphasis is on developing and demonstrating a modular software architecture for a generic, advanced engine control system that will result in lower software maintenance (operations) costs. It effectively accommodates software requirements changes that occur due to hardware. technology upgrades and engine development testing. Ground rules directed by MSFC were to optimize modularity and implement the software in the Ada programming language. MRECS system software and the software development environment utilize Commercial-Off-the-Shelf (COTS) products. This paper presents the objectives and benefits of the program. The software architecture, design, and development environment are described. MRECS tasks are defined and timing relationships given. Major accomplishment are listed. MRECS offers benefits to a wide variety of advanced technology programs in the areas of modular software, architecture, reuse software, and reduced software reverification time related to software changes. Currently, the program is focused on supporting MSFC in accomplishing a Space Shuttle Main Engine (SSME) hot-fire test at Stennis Space Center and the Low Cost Boost Technology (LCBT) Program.