Vaporization and Zonal Mixing in Performance Modeling of Advanced LOX-Methane Rockets
Initial modeling of LOX-Methane reaction control (RCE) 100 lbf thrusters and larger, 5500 lbf thrusters with the TDK/VIPER code has shown good agreement with sea-level and altitude test data. However, the vaporization and zonal mixing upstream of the compressible flow stage of the models leveraged empirical trends to match the sea-level data. This was necessary in part because the codes are designed primarily to handle the compressible part of the flow (i.e. contraction through expansion) and in part because there was limited data on the thrusters themselves on which to base a rigorous model. A more rigorous model has been developed which includes detailed vaporization trends based on element type and geometry, radial variations in mixture ratio within each of the “zones” associated with elements and not just between zones of different element types, and, to the extent possible, updated kinetic rates. The Spray Combustion Analysis Program (SCAP) was leveraged to support assumptions in the vaporization trends. Data of both thrusters is revisited and the model maintains a good predictive capability while addressing some of the major limitations of the previous version.
High-Area-Ratio Rocket Nozzle at High Combustion Chamber Pressure: Experimental and Analytical Validation
Experimental data were obtained on an optimally contoured nozzle with an area ratio of 1025:1 and on a truncated version of this nozzle with an area ratio of 440:1. The nozzles were tested with gaseous hydrogen and liquid oxygen propellants at combustion chamber pressures of 1800 to 2400 psia and mixture ratios of 3.89 to 6.15. This report compares the experimental performance, heat transfer, and boundary layer total pressure measurements with theoretical predictions of the current Joint Army, Navy, NASA, Air Force (JANNAF) developed methodology. This methodology makes use of the Two-Dimensional Kinetics (TDK) nozzle performance code. Comparisons of the TDK-predicted performance to experimentally attained thrust performance indicated that both the vacuum thrust coefficient and the vacuum specific impulse values were approximately 2.0-percent higher than the turbulent prediction for the 1025:1 configurations, and approximately 0.25-percent higher than the turbulent prediction for the 440:1 configuration. Nozzle wall temperatures were measured on the outside of a thin-walled heat sink nozzle during the test fittings. Nozzle heat fluxes were calculated front the time histories of these temperatures and compared with predictions made with the TDK code. The heat flux values were overpredicted for all cases. The results range from nearly 100 percent at an area ratio of 50 to only approximately 3 percent at an area ratio of 975. Values of the integral of the heat flux as a function of nozzle surface area were also calculated. Comparisons of the experiment with analyses of the heat flux and the heat rate per axial length also show that the experimental values were lower than the predicted value. Three boundary layer rakes mounted on the nozzle exit were used for boundary layer measurements. This arrangement allowed total pressure measurements to be obtained at 14 different distances from the nozzle wall. A comparison of boundary layer total pressure profiles and analytical predictions show good agreement for the first 0.5 in. from the nozzle wall; but the further into the core flow that measurements were taken, the more that TDK overpredicted the boundary layer thickness.
Design, fabrication and delivery of a high pressure LOX-methane injector
An injector for 3000 psia chamber pressure using liquid oxygen and gaseous methane propellants is presented. The injector is intended to be evaluated during a series of pressure-fed test firings using a water-cooled calorimeter chamber and a milled-slot regenerative chamber. Combustion efficiency, combustion stability, ignition and injector face heat transfer assessments were made for candidate injector body and pattern design approaches. This evaluation resulted in baselining an oxidizer post type manifold with a 60 element platelet coaxial swirler injector pattern. An axial acoustic resonator cavity was created at the injector/chamber interface.