Liquid Rocket Thrust Chambers (Progress in Astronautics and Aeronautics)

777 Pages·2004·8.95 MB·English

by  V. Yang

Liquid Rocket Thrust Chambers:
Aspects of Modeling, Analysis,
and Design
Edited by
Vigor Yang
PennsylvaniaStateUniversity
UniversityPark,Pennsylvania
Mohammed Habiballah
OfficeNationald’EtudesetdeRecherchesAe´rospatiales
Chaˆtillon,France
JamesHulka
Jacobs-SverdrupTechnology,Inc.
Huntsville,Alabama
Michael Popp
PrattandWhitneySpacePropulsion
WestPalmBeach,Florida
Volume 200
PROGRESS IN
ASTRONAUTICS AND AERONAUTICS
Paul Zarchan, Editor-in-Chief
MIT LincolnLaboratory
Lexington, Massachusetts
Publishedbythe
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ISBN1-56347-223-6
Progress in Astronautics and Aeronautics
Editor-in-Chief
PaulZarchan
MIT Lincoln Laboratory
Editorial Board
DavidA.Bearden RichardC.Lind
TheAerospaceCorporation UniversityofFlorida
JohnD.Binder RichardM.Lloyd
viaSolutions RaytheonElectronicsCompany
StevenA.Brandt FrankK.Lu
U.S.AirForceAcademy UniversityofTexasatArlington
FredR.DeJarnette AhmedK.Noor
NorthCarolinaStateUniversity NASALangleyResearchCenter
PhilipD.Hattis AlbertC.Piccirillo
CharlesStarkDraperLaboratory InstituteforDefenseAnalyses
AbdollahKhodadoust BenT.Zinn
TheBoeingCompany GeorgiaInstituteofTechnology
PeterH.Zipfel
AirForceResearchLaboratory
Acknowledgments
Publication of this volume was made possible through the substantial
contributions of a number of individuals and organizations. We would like to
firstthanktheauthorsofthepapersforsharingtheirtimeandtalentinpreparing
their manuscripts and carefully revising them. Many other individuals deserve
special recognition for reviewing the chapters in this volume; their names are
listed here:
D.Ballal J.Hulka M. Popp
V.Bazarov J.Ito R. Reitz
J.Bellan R. Jensen U.Renz
C. Bonniot T. Jiang C.-A.Schley
R. Carroll A.Kumakawa D.Seymour
Y.-S. Chen F. Lacas D.Stepowski
D.Counts P. Liang P. Strakey
C. Crowe W.Mayer D.Talley
D.Culver C. Merkle C. Tropea
C. Dexter K.Olson L. Vingert
I.Dubois M.Moser T.-S. Wang
S. Fisher M.Oschwald J. Wolfrum
K.Gross S. Pal P. K.Wu
M.Habiballah J.Peters J. Xin
D.Haeseler J.Pieper V.Yang
The invaluable assistance of Rodger Williams, Heather Brennan, and Janice
SayloroftheAIAAinthepreparationofthevolumeforpublicationisgratefully
acknowledged. We owe a large debt of gratitude to Mary Newby for managing
voluminous correspondence among editors, authors, reviewers, and the AIAA.
The technical drawing services provided by Danning You and Yanxing Wang
deserve special thanks. Last, but by no means least, we wish to thank Anna
Creesefor her outstandingtechnical editing expertise.
Financial support for the Second International Symposium on Liquid Rocket
Propulsion and the preparation of this volume was provided by the following
organizations.
- OfficeNational d’Etudes et de Recherches Ae´rospatiales (ONERA)
- Agence Spatiale Europe´enne
- CentreNational d’Etudes Spatiales(CNES)
- Snecma Moteurs
- Deutsches Zentrum Fu¨r Luft- und Raumfahrt(DLR)
- EADS Space TransportationGmbH
- United States Air Force European Office of Aerospace Research and
Development
xix
xx
Their sponsorship is gratefully acknowledged. We wish to express our deep
appreciation to Paul Kuentzmann for having hosted the symposium and for his
continued support to the international collaboration on space propulsion. He
deservesspecialthanks.WearealsoindebtedtoMitatBirkanandDieterPreclik
for their generous supportand encouragement.
Preface
Liquid-propellant rocket engines have been used as the primary propulsion
systemsinmostlaunchvehiclesandspacecraftsincetheinitialconquestofspace.
Eight decades after their first fabrication and test, however, many aspects of
modeling,analysis,anddesignofthrustchambersfortheseenginesstillpresent
important challenges. Certainly one reason for this continued challenge is the
complexity of the problem; although the basic concepts are well established,
many of the detailed physiochemical processes of liquid-propellant combustion
remain unresolved. Another reason is the difficulty and significant expense of
conducting research and development in the harsh and hazardous environments
ofliquidrocketthrustchambers.Improvementsinperformanceforfuturerocket
engines may require that internal pressures and heat flux, already substantial,
continuetoincrease,renderingtheproblemevenmorechallenging.Furthermore,
any design work addressing performance, life, reliability, and safety for future
thrust chamber development will benefit greatly from an improved under-
standingofthechemicalandphysicalprocessesandtheresultingformulationand
useof suitable models that can beincorporated into advancedanalysistools.
Investments in this field have slowed over the past 30 years, and important
resultsandreferencepublicationseitherhavedisappearedorhavenotbeenmade
widelyorpubliclyavailable.TheUnitedStatesandtheformerSovietUnionhave
made only sporadic investments since their significant advancements in the
1950s, ’60s, and ’70s. Europe, China, and Japan, on the other hand, have made
major investments in recent decades. At the same time, there have been
significant improvements in computational and experimental techniques, and a
growingpracticalexperiencewithfull-scalerocketenginesworldwide,thathave
advanced the state of the art. Unfortunately, the smaller scale and narrower
dissemination of the literature on this work have limited the widespread
utilization of these advances. Existing publications are scattered throughout
various journals, technical reviews, conference proceedings, and progress
reports.
Thereisconsequentlyadistinctneedforacomprehensivetexttoorganizeand
make readily available the latest results and developments, and to promote
additionalinsight,research,andcollaborationonthetopicsofmodeling,analysis,
and design of liquid rocket thrust chambers. There has not been a major
publicationonthistopicsinceLiquidRocketsandPropellants,in1960.(Volume
2 inthe AIAAProgress inAeronautics andAstronautics Series, edited by L.E.
Bollinger, M. Goldsmith, and A. W. Lemmon, Jr.) A volume to capture and
presenttherecentadvancesandcurrentunderstandinginthefieldwastherefore
considered an important contribution to the research, industrial, and academic
communities involved in the design, development, and testing of liquid rocket
thrust chambers.
xvii
xviii
The present volume compiles results from many of the research and
development programs conducted over the last several decades across the
international community. One of the driving interests behind the production of
thisvolumewastocovertheinternationalscope,whichwasmadepossiblebythe
significantchangesin the politicallandscape over the past decade.
The original material and impetus for this volume came from the Second
International Symposium on Liquid Rocket Propulsion, hosted by l’Office
National d’Etudes et deRecherches Ae´rospatiales,at Chaˆtillon,France, inJune
of1995.Thismeetingwasthesecondinaseriesofsymposiadesignedtoprovide
opentechnicalexchangesacrosstheinternationalcommunityintheliquidrocket
field. At the symposium, technical presentations were made by leading experts
from eight countries, including nearly every major governmental and corporate
organization.Likeitspredecessor,thismeetingprovidedauniqueopportunityfor
presentation and discussion of work from the Commonwealth of Independent
States and from China that had notbeen seen previouslyinthe West.
This volume is designed as a reference text, with a balance of fundamental
scientific and technological works. It is organized into five subject areas,
consistent with a stepwise approach through the design and analysis of thrust
chambers,including:1)injectionandatomizationprocesses;2)combustionand
ignitionprocesses;3)nozzledesignandoptimization;4)chamberdynamics,heat
transfer, and performance; and 5) influence of engine system design. Twenty
chaptersareincluded,allpreparedandreviewedbyleadingexpertsinthisfield.
Thevolumecanbeusedandenjoyedbyengineers,researchers,andscientistsin
industry, government, and academia who are involved in rocket propulsion
research.Thestructuringofthisvolumeasareferencealsowillrenderitusefulto
those inotherfields involved inthe design ofcombustiondevices.
Vigor Yang
Mohammed Habiballah
James Hulka
MichaelPopp
November2004
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Chapter1 Propellant Injection Systems and Processes . . . . . . . . . . 1
JacksonI.ItoGenCorpAerojetPropulsionDivision,Sacramento,California
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RocketApplicationDesignRequirements . . . . . . . . . . . . . . . . . . . . 2
ThrustLevelandOperatingPressure. . . . . . . . . . . . . . . . . . . . . . . 2
PropellantType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EngineCycleorFeedSystem. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CommonCombustionDeviceDevelopmentRisks . . . . . . . . . . . . . . . 6
CombustionInstability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CombustionChamberOverheatingandBurnout. . . . . . . . . . . . . . . . . 7
InjectorFaceErosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LowThrustChamberAssemblyPerformance . . . . . . . . . . . . . . . . . . 8
UnsafeTransients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
InjectionSystemDesignConsiderations . . . . . . . . . . . . . . . . . . . . . 9
EnginePressureSchedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
NozzleExpansionRatio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ContractionRatio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ChamberLength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
InjectionElementandPattern. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CriticalCombustionProcesses. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
InjectorManifoldDistribution . . . . . . . . . . . . . . . . . . . . . . . . . . 11
InjectorSprayAtomization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PropellantDropletVaporization. . . . . . . . . . . . . . . . . . . . . . . . . . 13
BipropellantMixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CandidateInjectorsforLiquidRocketApplications . . . . . . . . . . . . . . 13
CoaxialJetInjectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ImpingingJetInjectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ParallelJet(Showerhead)Injectors. . . . . . . . . . . . . . . . . . . . . . . . 16
InjectorDesignSynthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ConclusionsandRecommendations. . . . . . . . . . . . . . . . . . . . . . . . 17
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter2 Design and Dynamics ofJet and Swirl Injectors . . . . . . . 19
VladimirBazarovMoscowAviationInstitute,Moscow,RussiaandVigorYang
andPuneeshPuriPennsylvaniaStateUniversity,UniversityPark,Pennsylvania
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ClassificationofInjectorsandMethodsofMixtureFormation . . . . . . . . . 22
vii
viii
LiquidInjectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gas-LiquidInjectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
IntensificationofPropellantAtomizationandMixinginLiquidInjectors . . 41
IntensificationofPropellantAtomizationandMixinginGas-LiquidInjectors . 45
TheoryandDesignofLiquidMonopropellantJetInjectors. . . . . . . . . . 45
FlowCharacteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
EffectofInjectorConfiguration. . . . . . . . . . . . . . . . . . . . . . . . . . 46
FlowCoefficient. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DesignProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TheoryandDesignofGaseousMonopropellantJetInjectors. . . . . . . . . 51
FlowCharacteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DesignProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TheoryandDesignofGas-LiquidJetInjectors . . . . . . . . . . . . . . . . . 53
TheoryandDesignofLiquidMonopropellantSwirlInjectors . . . . . . . . 56
FlowCharacteristicsofIdealSwirlInjector . . . . . . . . . . . . . . . . . . . 57
FlowCharacteristicsofRealSwirlInjectors . . . . . . . . . . . . . . . . . . . 66
EffectofViscosityonInjectorOperation. . . . . . . . . . . . . . . . . . . . . 68
DesignProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
TheoryandDesignofLiquidBipropellantSwirlInjectors . . . . . . . . . 72
InjectorswithExternalMixing . . . . . . . . . . . . . . . . . . . . . . . . . . 72
InjectorswithInternalMixing. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ModulationofLiquidSprayCharacteristicsofSwirlInjectors. . . . . . . . 77
DesignofGasSwirlInjectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DesignProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SelectionofGeometricDimensionsandFlowParameters. . . . . . . . . . . . 89
DynamicsofLiquidRocketInjectors. . . . . . . . . . . . . . . . . . . . . . . 90
LinearDynamicsofJetInjectors . . . . . . . . . . . . . . . . . . . . . . . . . 92
LinearDynamicsofSwirlInjectors. . . . . . . . . . . . . . . . . . . . . . . . 94
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Chapter3 Atomization inCoaxial-JetInjectors . . . . . . . . . . . . . . . 105
LucienVingertandPierreGicquelONERA,Palaiseau,France,MichelLedoux
andIsabelleCare´ CORIA,Universite´ deRouen,Rouen,France,and
MichaelMicciandMichaelGlogowskiPennsylvaniaStateUniversity,
UniversityPark,Pennsylvania
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PhenomenologicalDescriptionandLiteratureReview. . . . . . . . . . . . . 106
GeneralSchemeofJetDisintegrationandDropFormation . . . . . . . . . . . 106
StudiesofElementaryProcesses . . . . . . . . . . . . . . . . . . . . . . . . . 109
NumericalSimulationsoftheAtomizationProcess . . . . . . . . . . . . . . . 111
DerivationofDropletSizeDistributionFunctions. . . . . . . . . . . . . . . . 111
InvestigationsofAtomizationinShearCoaxialInjectors . . . . . . . . . . . 111
ExperimentalandTheoreticalInvestigationatAtmosphericPressurewith
Simulants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
PhotographicStudiesUsingCryogenicFluids(Liquid/GaseousNitrogen). . . 125
LOXSprayCombustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ix
Acknowledgment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Chapter4 Liquid Bipropellant Injectors . . . . . . . . . . . . . . . . . . . . 141
WilliamE.Anderson,MatthewR.Long,andStephenD.HeisterPurdue
University,WestLafayette,Indiana
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ImpingingJetInjector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
GeneralDescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ApplicationsandDesignGuidelines . . . . . . . . . . . . . . . . . . . . . . . 144
MechanisticStudy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ModelingApproaches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
BicentrifugalSwirlInjector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
GeneralDescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ApplicationsandDesignGuidelines . . . . . . . . . . . . . . . . . . . . . . . 152
ModelingApproaches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
PintleInjector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
GeneralDescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ApplicationsandDesignGuidelines . . . . . . . . . . . . . . . . . . . . . . . 159
MechanisticStudy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
SummaryandConclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Chapter5 Distortion and Disintegration of Liquid Streams. . . . . . . 167
WilliamA.SirignanoandCarstenMehringUniversityofCalifornia,Irvine,
California
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
FormulationofGoverningEquations . . . . . . . . . . . . . . . . . . . . . . . 173
RoundJetAnalyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
TemporalStabilityAnalysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
SurfaceEnergy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
SpatialStabilityAnalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
NonlinearEffects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ViscousEffects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
SprayControlviaElectricFields. . . . . . . . . . . . . . . . . . . . . . . . . 188
CoaxialJets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
PlanarSheetAnalyses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
LinearTheory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
FanSheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
SimplifiedBreakupTheories . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
NonlinearTheory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
AnnularFreeFilms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
LinearTheory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
NonlinearTheory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
EffectofSwirl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
ConicalFreeFilms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
ConcludingRemarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241