Application of computational fluid dynamics to the design of the film cooled STME subscale nozzle for the National Launch System

The status of computational fluid dynamics (CFD) calculations for the Space Transportation Main Engine (STME) film/dump cooled nozzle design is presented, with an emphasis on the timely impact of CFD on the design of the sub-scale nozzle coolant system. The following aspects of the sub-scale coolant delivery system were analyzed with CFD: 1) a design trade study of a mechanical flow splitting device for uniform distribution of the subsonic cavity flow, 2) a design trade study of the subsonic cavity lip to achieve film integrity, and 3) an analysis of the primary flow interaction with the core/secondary coolant streams. All design calculations were performed with the Generalized Aerodynamic Simulation Program (GASP), a 3-D, multi-block, generalized Navier-Stokes code capable of solving with frozen, finite-rate or equilibrium chemical kinetics. The initial design of the subsonic cavity flow used square posts to distribute the sonic orifice jets into a uniform flow. Calculations for this design indicated that an unacceptable mal-distribution of film occurred. Design modifications involving curved and slotted posts were computed in an effort to uniformly distribute the secondary coolant flow. Analysis of these configurations showed that although the flowfield improved in uniformity, it was still unacceptable, especially at higher feed pressures. Results from these studies were then incorporated into a design that resulted in the insertion of a porous metal ring into the subsonic cavity. Subsequent water flow model studies showed that this concept was successful in uniformly distributing flow exiting the cavity. In addition to the design of the subsonic cavity, CFD was also used to analyze the secondary coolant lip and the primary flow interaction with the core/secondary coolant streams. A series of calculations were first performed to modify the subsonic cavity lip contour. The flow over the modified lip was then computed simultaneously with the primary injectors to determine the impact of the subsonic coolant stream on the primary slot jets. Pressure, temperature, velocity, and coolant mass fraction contours are presented for these configurations. Information is given in viewgraph form.