rolls-royce high mach propulsion utc s. heister, w. anderson school of aeronautics &...

Rolls-Royce High Mach Propulsion UTC

S. Heister, W. AndersonSchool of

Aeronautics & Astronautics

I. Mudawar, P. SojkaSchool of

Mechanical Engineering

Rolls-RoyceUniversity Technology Center

in High Mach Propulsion – Year 1 Review and Status Update


Outline

1. UTC Overview & Year 1 Goals – Heister

2. Fuel/Air HEX Project Status – Mudawar

3. Supercritical Fuel Injection Project Status – Sojka

4. Afterburner Cooling Project Status – Anderson

5. Summary & Year 2 Plans - Heister


Senior UTC Personnel• Dr. Steve Heister, UTC Lead, propulsion, two-phase flows,

engine cycles• Dr. Bill Anderson, combustors, fuel stability• Dr. Issam Mudawar, high heat-flux heat transfer• Dr. Paul Sojka, supercritical “atomizer” design & spray

characterization• Dr. Jay Gore, IR spectroscopy• Mr. Scott Meyer, Senior Engineer, facilities &

instrumentation• Ms. Melanie Thom (Baere Aerospace Consulting): over 15

years experience in fuel systems


Collaborators & Students in UTC

• Fuel/air HEX project– Mr. John Tsohas, M.S. student– Mr. Neal Herring, Ph.D. student– Mr. Tim Kibbey, M.S. student and Rolls-Royce Fellowship recipient– Mr. Adam Finney, undergraduate student

• A/B cooling project:– Mr. Tom Martin, M. S. student and Ross Fellowship recipient– Mr. Eric Briggs, M. S. student

• Supercritical fuel injection project:– Mr. Greg Zeaton, M. S. student– Mr. Omar Morales, MARC/AIM program


High Mach Propulsion UTC 5 Year PlanTwo-phase Fuel Injection

Design injector(s) for two-phase fuel mixture flow into combustor

• Test at least two injector designs to develop data base for mass-driven spray formation

• Develop design models to treat mass-transfer driven spray formation

• Predict mean drop size and drop size distribution in terms of atomizer operating conditions, nozzle geometry, and fuel physical properties

• Build on existing effervescent atomizer model development

• Include influence of fuel vaporization/cracking, which can produce liquid/vapor mixture

• Develop design models to treat mass-transfer driven spray evolution

• Predict patternation, cone angle, entrainment of surrounding air, and penetration

• Build on existing effervescent atomizer model development (effervescent Diesel injection)

• Eventually include vapor distribution as well as liquid distribution


3. Supercritical Fuel (SCF) Injection Project Status


Supercritical Fluid (SCF) Injection Experiment

Identify performance limitations for SCF injection and develop design guidelines for future high-Mach engines

A literature review of previous supercritical fluid injection studies suggests fuel superheat, atomizer geometry, and gas/fluid density ratio are the key variables that effect “Spray” cone angle Patternation “Spray” momentum rate distribution

Goal


SCF Injection – Fluid Selection Jet fuel ruled out

for initial experiments

HOQ is engineering approach to decision making

Surrogate “fuel” selected based on human factors and functional performance


CO2 selected as surrogate “fuel” for first experiments Relatively safe, inert, non-toxic Inexpensive, readily available Supercritical thermodynamic and transport properties are already well defined Non-combustible so no need to redesign existing spray apparatus Tc “low” so existing apparatus can be used

SCF Injection – Fluid Selection


Baseline Injector and Preliminary Results


SCF Injection – Baseline Pressure Swirl Injector

Pressure swirl atomizer selected as baseline configuration for evaluation Larger cone angles (better distribution of fuel mass in the combustion chamber) than demonstrated in previous experiments using plain orifice injectors with SCF’s Injector geometry is easily modified to obtain desired spray characteristics


SCF Injection- Baseline Pressure Swirl Injector Design


SCF Injection - Preliminary flow visualizations

9.2 g/s 9.2 g/s

H2O-in-air (1) and H2O-in-H2O (2) flows demonstrate the

influence of density ratio on spray evolution

A density ratio similar to H2O-in-H2O (near unity) will

be present when SCF experiments are performed

(1) (2)


SCF Injection - Preliminary flow visualization

An overall

decrease in

cone angle with

increased

density ratio

was observed


SCF Injection - Experimental apparatus

Test vessel CO2 supply system

Air supply system DAQ system


SCF Injection – Test vessel

Windowed chamber

Injector

Originally used for

Diesel injection Recently upgraded to

withstand pressures

of 1500 psi (10.3 MPa) Reconfigured for

supercritical CO2

operation (O-rings,

supply lines, etc.)


SCF Injection – CO2 supply system


SCF Injection – Co-flow air supply system


SCF Injection - Test rig

Air heater

CO2 heater

Test vessel

Gas booster

Opticaltable

PID heatercontrols

Meteringvalve


SCF Injection – Test rig

TC probe

Coriolis flow meter

Co-flow air manifold

Test vessel

Dome regulator


SCF Injection - DAQ & control

SCXI interface

TC panel

Control output panel

Analog input panel


SCF DAQ – optical patternator

Optical patternator

developed at Purdue

0.5

0.6

0.7

0.8

0.9

1

0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102

108

114

120

126

Pixel Number

Sp

ray

Pat

tern

(0

Deg

rees

)

0.5

0.6

0.7

0.8

0.9

1

0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102

108

114

120

126

Pixel Number

Sp

ray

Pat

tern

(0

Deg

rees

)


SCF DAQ – Momentum rate probe

Technique refined at Purdue over the last ten years Characterizes spray penetration via force balance To be installed in test vessel


SCF Injection – Overview of system capabilities

Heat and pressurize CO2 above its critical T and p and inject into ambient environment whose p and T exceed critical CO2 values

Operate at any combination of p and T above CO2 critical values

Obtain shadowgraphs of spray cone angle Uncertainty: +/-5 %

Obtain mass distribution data Uncertainty: +/-0.5%

Obtain momentum rate data for spray penetration Uncertainty: +/-1%


SCF Injection – Status

Facilities near completion waiting on accumulator (to damp

injection pressure pulsations) TRR next week DAQ software optimization Configure optics SCF experiments will begin by the end of

January 2004


Gearing Status• Leveraging of UTC funds is a primary goal• Current Status

– NASA MSFC “Risk Reduction for the ORSC Cycle”• ~ $0.5M w/ ~ 1/3 focused on thermal management

– NASA GRC “Flow Boiling Critical Heat Flux in Reduced Gravity” (~$0.5M)

– RR/AADC Industrial Affiliates Fellowship for Tim Kibbey– Purdue Ross Fellowship for Tom Martin– U/G Honors thesis project Adam Finney– MARC/AIM summer fellowship for Omar Morales– AFOSR MURI in Hypersonic Transition


Summary – High Mach UTC

• Schedule on track to fulfill Year 1 goals– Research team in place– Fuel Thermal Management Lab nearly complete– Facility mods to spray diagnostics lab nearly

complete

• Gearing/leveraging efforts already successful, future efforts to explore projects with AFRL and/or NASA GRC

rolls-royce high mach propulsion utc s. heister, w. anderson school of aeronautics &...

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