NASA CR - 135141 (HIS&-CS-135141) bDV&NC?a HIGH PEdSSURB N77-23194 ESGXNS STUDY FOR NIXEC-UODR VEHICLE IPPLICBTXONS Final Beport (Aerojet Liquid socket Co.) 319 y HC A14/HF 901 CSCL 21H Unclas G3/20 29365 NASA \ ADVANCED HIGH PRESSURE ENGINE STUDY FOR MIXED-MODE VEHICLE APPLICATIONS Final Report by W. P. Luscher and 3. A. Mellish AEROJET t IQUI D ROCKET COMPANY Prepared for NATIONAL AERONAUTICS AND SPACE ADNINISTRATION NASA Lewis Research Center Contract NAS 3-1 9727 - - 1. Report No. 2. Gavernnient Access~onNo. 3. Rec~p~ent'sCatalog No. NASA CR- 135141 4. T~lleand Sublltle 15. Rcporl Date Advanced High Pressure Engine Study for Mixed-Mode Vehicle Applications, Final Report I 1 8. Perlorm~ngOrgantzallon Report No. W. P. Luscher and J. A. Mellish I 9. Pedorm~ngOrgan~zalton Name and Address Aerojet Liquid Rocket Company - Post Office Box 13222 Sacramento, California 95813 NAS3-19727 13. Type 01 Report and Per~odCovered qency Name and Address Contractor Reporr;, Final - National Aeronautics and Space Administration 14. Swnsor~ngAgency Code Washington, D. C. 20546 I 15. Supplementary Notes Project Manager, D. D . Scheer , Chemi cal Energy Division, NASA-Lewis Research Center, Cleveland, Ohio 16. High pressure liquid rocket engine design, performance, weight, envelope and operational characteristics were evaluated for a variety of candidate engines for use in mixed-mode, single-stage-to-orbi t appl ications. Propellant property and performance data were obtained for candidate Mode 1 fuels which included; RP-1, RJ-5, hydrazine, monomethyl -hydrazine, and methane. The common oxidizer was liquid oxygen. Oxygen, the candidate Mode 1 fuels, and hydrogen were evaluated as thrust chanber coolants. Oxygen, methane and hydrogen were found to be the nmt viable cooling candidates. Water, 1i thi um and sodium-potassi um were also evaluated as auxi 1iary coolant systems. Water proved to be the best of these but the system was heavier than those systems which cooled with the engine pro- pel 1ants. Engine weight and envelope parametric data were establ ished for candidate Mode 1, Mode 2 and dual-fuel engines. Delivered engine performance data was also calculated for all candidate Mode 1 and dual-fuel engine. Engines carried into prel iminary design were; (1) LOX cooled, LOXIRP-1 Mode 1, staged combustior cycle, (2) hydrogen cooled, LOXIRP-1 Mode 1, gas- generator cycle, and (3) dual-fuel LOX cooled, LOXIRP-1 Mode 1/LH2 Mode 2, staged combustion cycle. ---- --- 17. Key Words (Sgggested by Authcr(s\ Single-Stage-to-Orb i t Mixed-Mode Propulsion Unclassified - Unlimited High Pressure Liquid Rock c Engine Mode 1 and Mode 2 Dual -Fuel - - 19. Secur~tyClass~f. (ot lhls report) 20. Sec rr~tyClasslf. (of this page) -/%-NO. of Pages 122. Price' Unclassified I-Unclassified 304 *For sale by the National Technical Information Service, Springfield, Virginia 22151 FOREWORD The work described herein was performed at the Aerojet Liquid Rocket Company under NASA Contract NAS3-19727 with Mr. Dean D, Scheer, NASA-Lewis Research Center, as Project Manager. The ALRC Program Manager was Mr. Werner P. Luscher and the Project Engineer was Mr. Joseph A. Me11 ish. The technical period performance for the study was from 30 June 1975 to 30 June 1976. The authors wish to acknowledge the efforts of the following ALRC engineering personnel who contributed signi fi- cantly t~this report: R. E. Anderson L. L. Bickford A. T. Caffo R. L. Ewen J. W. Hidahl M. C. Huppert G. R. Janser J. E. Jellison C. J. O'Brien J. W. Salmon D. H. Saltzman M. Short K. Y. Wong We also wish to thank Mr. Rudi Beichel , ALRC Senior Scientist, for his comments and assistance throughout the study effort. TABLE OF CONTENTS Section Page I SUMMARY 1 A, Study Objectives and Scope B. Results and Conclusions II INTRODUCTION A. Background B. Purpose and Scope C. General Requirements D. Approach 111 TASK I - PROPELLANT PROPERTIES AND PERFORMANCE A. Objectives and Guidelines B . Physical and Thermodynamic Property Data C. Operational Considerations D. Combustion Gas Property Data E. Main Chamber Theoretical Performance Data TASK I1 - COOLANT EVALUATION A. Objectives and Gui del ines B. TCA Geometry and Mixture Ratio Selection C. Low Cycle Fatigue Analysis D. Thermal Analysis TASK I11 - CYCLE EVALUATION A. Objectives and Guidel ines B. Task I11 Delivered Performance C. Engine Cycle Power Balances TASK IV - ENGINE WEIGHT AND ENVELOPE A. Objective and Guidel ines B. Base1 ine Engine Weight Statements C. Parametric Weight Data D. Parametric Envelope Data VII TASK V - AUXILIARY COOLANT FEASIBILITY A. Objectives and Gui del ines B. Auxi 1 iary Coolant Properties TABLE OF CONTENTS (cont. ) Section Paqe I C. Materials Compatibility 154 D. Chamber Cool ing 156 E. Engine Data 158 IP VIII TASK VI - ENGINE PRELIMINARY DESIGN 163 -.. A. Objectives and Guide1 ines 163 5. Ejost Pump Drive Selection 166 C. Boost Pump NPSH Effects 170 D. Engine Design and Operating Specifications 171 Model 1 LOX/RP-1 Baseline Design 178 a. Configuration and Nominal Operating 178 Conditions b. Engine Operation and Control 178 c. Start and Shutdown Data 186 d. Design and Off-Design Engine Performance 186 e. Engine Mass Properties Data 186 Dual -Fuel Engine Design 191 a. Configuration and Nominal Operating 191 Conditions b. Engine Operation and Control 193 c. Start and Shutdown Data 203 d. Design and Off-Desi gn Engine Performance 203 e. Engine Mass Properties Data 203 Alternate Mode 1 Engine Design 21 0 a. Configuration and Nominal Operating 21 0 Conditions b. Engine Operation and Control 21 0 c. Start and Shutdown Data 220 d. Design and Off-Design Engine Performance 220 e. Engine Mass Properties Data 220 E. Turbomachinery Design 224 F. Thrust Chamber Design 247 1. Performance 247 2. Thermal Analysis 257 G. Main Injector Design 265 H. Preburner Design 268 I. Valve Selection and Sizing 282 J. Material Selection 287 TABLE OF CONTENTS (cont.) Section Page IX CONCLUSIONS AND RECOMMENDATIONS 292 A. Concl us i ons B. Recomnendations for Technology Work REFERENCES LIST OF TABLES -'1'7bl e No. Page I Engine Preliminary Design Data Sumnary II Para11 el Burn Mixed-Mode Vehicle Definition I11 Series Burn Mixed-Mode Vehicle Definition IV Baseline Engine Definitions V Properties of Candidate Propel 1ants VI Vapor Pressure of RJ-5 VII Density of RJ-5 VIII Viscosity of RJ-5 IX Heat Capacity and Thermal Conductivity of RJ-5 X Extrapolated Heat Capacities of Methane XI Extrapolated Densities of Methane XII Viscosity of Methane XI11 Thermal Conductivity of Methane XIV Propel 1ant Cost Sumnary xv LOX/RJ-5 Main Chamber Gas Property Data xv I LOX/RP-1 Main Chamber Gas Property Data XVII LOX/MMH Main Chamber Gas Property Data XVIII LOX/N2H4 Main Chamber Gas Property Data XIX LOX/LH2 Main Chamber Gas Property Data X X LOX/CH4 Main Chamber Gas Property Data XX I LOX/RJ-5 Oxidizer-Rich Preburner Gas Property Data Sumna ry XXII LOX/RP-1 Oxidizer-Rich Preburner Gas Property Data Sumnary XXIII LOX/MMH Oxidizer-Rich Preburner Gas Property Data Sumnary XXIV LOX/N2H4 Oxidi zer-Ri ch Preburner Gas Property Data Sumnary xxv LOX/LH2 Oxidizer-Rich Preburner Gas Property Data Sumnary XXVI LOX/CH4 Oxi dizer-Ri ch Preburner Gas Property Data Sumnary XXVI I LOX/MMH Fuel -Rich Preburner Gas Property Data Summary XXVI II LOX/N2H4 Fuel-Rich Preburner Gas Property Data Summary LIST OF TABLES (cont.) Table No. XXIX LOX/LH2 Fuel-Rich Preburner Gas Property Data Sumry XXX LOXIRJ-5 %el-Rich Preburner Gas Property Data Sumnary XXXI LOX/RP-1 Fuel-Rich Preburner Gas Property Data Sumnary XXXI I LOX/CH4 Fuel-Rich Preburnsr Gas Property Data Sumry XXXI II Cool ant Eva1 uation Study Guide1 ines XXXIV Task I1 Mode 1 Engine Geometry and Mixture Ratio Selection Sumnary xxxv Task I1 Chamber Design Limits XXXVI Number of Cool ant Channel s in Combustion Chamber xxxv II Task I1 Coolant Evaluation Sumnary XXYVI II Maximum Bearing DN Values XXXIX Face Contact Seal Maximum PV, FV and PFV Factors XL Task I11 Turbine Inlet Temperature Selections XL I Task I11 Cycle Evaluation Summary XLII Task I11 Candidate Mode 1 Engine Comparisons XLIII Task IV - Engine Weight Definitions XLIV Task IV - Base1 ine Engine Weight Statements XLV Candidate Mode 1 Engine Envelope Parametrics XLV I Candidate Mode 1 Engine Envelope Parametri cs XLVI I Hydrogen Cooled , Gas Generator Cycle Engi ne Envelope Parametrics XLVI I1 Hydrogen Cooled , Gas Generator Cycl e Engi ne Envelope Parametri cs XLIX Dual -Fuel Engine Envelope ParametriL; L Mode 2 Engine Envelope Parametri cs L I Properties of Candidate Auxi 1i ary Cool ants LII Density of Liquid NaK (56) LIII Viscosity of Liquid NaK (56) LIV Summary of Task V Chamber Designs LV Task V Auxiliary Cooled Engine Sumnary viii I LIST OF TABLES (cont. Table No. Page LV I Mode 1 LOX/RP-1 Engi ne Operati ng Speci f ications, 182 Nominal MR=2.9 L'JII Mode 1 LOXIRP-1 Base1 ine Engi ne Pressure Schedule, 185 Nominal MR=2.9 LVI II Sequence of Operations, Base1 ine LOXIRP-1 187 LIX Mode 1 LOXIRP-1 Base1 ine Start and Shutdown 188 Transient Data Summary LX Mode 1 LOXIRP-1 Baseline Engine Design and Off-Design '189 MR Performance LXI Mode 1 LOXIRP-1 Base1 ine Engi ne Wei ght Statement 190 LXI I Dual -Fuel Nominal Engine Operating Specifications 196 LXI II Dual -Fuel , Mode 1 Nomi nal Engine Pressure Schedule 201 LXIV Dual -Fuel , Mode 2 Nominal Engine Pressure Schedule 202 LXV Sequence of Operation Dual -Fuel Engine 204 LXVI Dual-Fuel Engine Start and Shutdown Transient Data 206 Summary LXVI I Dual-Fuel, Mode 1 Design and Off-Design MR Performance 207 LXVI II Dual-Fuel, Mode 2 Design and Off-Design