Unsteady Flow Simulations in Support of the SSME HEX Turning Vane Cracking Investigation with the ATD HPOTP

Unsteady flow computations are being performed with the P&W (ATD) and the Rocketdyne baseline configurations of the SSME LO2 turbine turnaround duct (TAD) and heat exchanger (HEX). The work is in support of the HEX inner turning vane cracking investigation. Fatigue cracking has occurred during hot firings with the P&W configuration on the HEX inner vane, and it appears the fix will involve changes to the TAD splitter vane position and to the TAD inner wall curvature to reduce the dynamic loading on the inner vane. Unsteady flow computations on the P&W baseline and fix and on the Rocketdyne baseline reference follow steady-flow screening computations done by MSFC/ED32 on several trial configurations arriving at the fix. The P&W TAD inlet velocity profile has a strong radial velocity component that directs the flow toward the inner wall and raises the local velocity a factor of two and the dynamic pressure a factor, of four. The fix is intended to redistribute the flow more evenly across the HEX inner and outer vanes like the Rocketdyne baseline reference. Vane buffeting at frequencies around 4,000 Hz is the leading suspected cause of the problem. Our simulations (work in progress) are being done with the USA 2D axisymmetric code approximating the flow as axisymmetric u+v 2D (axial, u, and radial, v, components only). The HEX coils are included in the model to make sure the fix does not adversely affect the HEX environment. Turbulent kinetic energy, k, levels where k = 1/2 v' rms2 are locally as high as 10,000 ft2/sec2 for the P&W baseline at the engine interface (between the TAD and HEX) at the HEX inner vane location. However, k is less than 8,000 on the HEX outer vane and only about 4,500 on the HEX inner vane for the Rocketdyne baseline. Unsteady turbulence intensity, v'rms/v, and pressure, p', are being computed in the present computations to compare with steady-flow Reynolds-averaged computations where p'rms = const (pk) for overall rms random turbulence from 0.1 to 12,000 Hz frequency. Random overall static, p'rms fluctuations as large as 1.7 psi are estimated from k on the HEX inner vane for the P&W baseline configuration but only about 0.7 psi for the Rocketdyne configuration.