Rolls-Royce High Mach Propulsion UTC S. Heister, W. Anderson School of Aeronautics & Astronautics I. Mudawar, P. Sojka School of Mechanical Engineering Rolls-Royce University Technology Center in High Mach Propulsion – Year 1 Review and Status Update

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC High Mach Propulsion UTC 5 Year Plan Two-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

Rolls-Royce High Mach Propulsion UTC 3. Supercritical Fuel (SCF) Injection Project Status

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC  CO 2 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  T c “low” so existing apparatus can be used SCF Injection – Fluid Selection

Rolls-Royce High Mach Propulsion UTC Baseline Injector and Preliminary Results

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC SCF Injection- Baseline Pressure Swirl Injector Design

Rolls-Royce High Mach Propulsion UTC SCF Injection - Preliminary flow visualizations 9.2 g/s  H 2 O-in-air (1) and H 2 O-in-H 2 O (2) flows demonstrate the influence of density ratio on spray evolution  A density ratio similar to H 2 O-in-H 2 O (near unity) will be present when SCF experiments are performed (1) (2)

Rolls-Royce High Mach Propulsion UTC SCF Injection - Preliminary flow visualization  An overall decrease in cone angle with increased density ratio was observed

Rolls-Royce High Mach Propulsion UTC SCF Injection - Experimental apparatus  Test vessel  CO 2 supply system  Air supply system  DAQ system

Rolls-Royce High Mach Propulsion UTC 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 CO 2 operation (O-rings, supply lines, etc.)

Rolls-Royce High Mach Propulsion UTC SCF Injection – CO 2 supply system

Rolls-Royce High Mach Propulsion UTC SCF Injection – Co-flow air supply system

Rolls-Royce High Mach Propulsion UTC SCF Injection - Test rig Air heater CO 2 heater Test vessel Gas booster Optical table PID heater controls Metering valve

Rolls-Royce High Mach Propulsion UTC SCF Injection – Test rig TC probe Coriolis flow meter Co-flow air manifold Test vessel Dome regulator

Rolls-Royce High Mach Propulsion UTC SCF Injection - DAQ & control SCXI interface TC panel Control output panel Analog input panel

Rolls-Royce High Mach Propulsion UTC SCF DAQ – optical patternator  Optical patternator developed at Purdue

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC SCF Injection – Overview of system capabilities  Heat and pressurize CO 2 above its critical T and p and inject into ambient environment whose p and T exceed critical CO 2 values  Operate at any combination of p and T above CO 2 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%

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC 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

Rolls-Royce High Mach Propulsion UTC 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