Future Vertical Lift Propulsion Systems & Associated S&T Challenges
No abstract available
Suder, Kenneth L.↗
Engineering topics
Suder, Kenneth L.
Publications and source records attributed to Suder, Kenneth L..
Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes
The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. To develop the test matrix of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method (COMDES-MELT) was enhanced by computing key parameters through the fan-stator at multiple span wise locations, in order to increase the fidelity with the current mean-line method. The Icing Wedge static wet bulb temperature thresholds were applicable for determining the risk of ice accretion in the fan-stator, which is thought to be an adiabatic region. At some operating conditions near the splitter-lip region, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion, and the Icing Wedge was not applicable to predict accretion at that location. A simple order-of-magnitude heat transfer model was implemented into the COMDES-MELT code to estimate the wall temperature minimum and maximum thresholds that support ice accretion, as observed by video confirmation. The results from this model spanned the range of wall temperatures measured on a previous engine that experienced ice accretion at certain operating conditions.
Veres, Joseph P.↗
NASA's Role in Gas Turbine Technology Development: Accelerating Technical Progress via Collaboration Between Academia, Industry, and Government Agencies
Given the maturity of the gas turbine engine since its invention and also considering the limited and flattened level of resources expected to be allocated for NASA aeronautics research and development, we ask the question are NASA technology investments still needed to enable future turbine engine-based propulsion systems? If so, what is NASA’s unique role to justify NASA’s investment? To address this topic, we will first review the accomplishments and the impact that NASA Glenn Research Center has made on turbine engine technologies over the last 78 years. Specifically, this paper discusses NASA’s role and contributions to turbine engine development, specific to both 1) NASA’s role in conducting experiments to understand flow physics and provide relevant benchmark validation experiments for Computational Fluid Dynamics (CFD) code development, validation, and assessment; and 2) the impact of technologies resulting from NASA collaborations with industry, academia, and other government agencies. Note that the scope of the discussion is limited to the NASA technology contributions with which the author was intimately associated, and does not represent the entirety of the NASA contributions to turbine engine technology. The specific research, development, and demonstrations discussed herein were selected to both 1) provide a comprehensive review and reference list of the technology and its impact, and 2) identify NASA’s unique role and highlight how NASA’s involvement resulted in additional benefit to the gas turbine engine community. Secondly, we will discuss current NASA collaborations that are in progress and provide a status of the results. Finally, we discuss the challenges anticipated for future turbine engine-based propulsion systems for civil aviation and identify potential opportunities for collaboration where NASA involvement would be beneficial. Ultimately, the gas turbine engine community will decide if NASA involvement is needed to contribute to the development of the design and analysis tools, databases, and technology demonstration programs to meet these challenges for future turbine engine-based propulsion systems.
Suder, Kenneth L.↗
Environmentally Responsible Aviation: Propulsion Research to Enable Fuel Burn, Noise and Emissions Reduction
The NASA Environmentally Responsible Aviation (ERA) program is maturing technologies to enable simultaneous reduction of fuel burn, noise and emissions from an aircraft engine system. Three engine related Integrated Technology Demonstrations (ITDs) have been completed at Glenn Research Center in collaboration with Pratt Whitney, General Electric and the Federal Aviation Administration. The engine technologies being matured are a low NOx, fuel flexible combustor in partnership with Pratt Whitney, an ultra-high bypass, ducted propulsor system in partnership with Pratt Whitney FAA and high pressure ratio, front-stage core compressor technology in partnership with General Electric. The technical rationale, test configurations and overall results from the test series in each ITD are described. ERA is using system analysis to project the benefits of the ITD technologies on potential aircraft systems in the 2025 timeframe. Data from the ITD experiments were used to guide the system analysis assumptions. Results from the current assessments for fuel burn, noise and oxides of nitrogen emissions are presented.
Ultra-High Bypass↗
NASA Environmentally Responsible Aviation Projects Propulsion Technology Phase I Overview and Highlights of Accomplishments
The NASA Environmentally Responsible Aviation (ERA) Project is focused on developing and demonstrating integrated systems technologies to TRL 4-6 by 2020 that enable reduced fuel burn, emissions, and noise for futuristic air vehicles. The specific goals aim to simultaneously reduce fuel burn by 50%, reduce Landing and Take-off Nitrous Oxides emissions by 75% relative to the CAEP 6 guidelines, and reduce cumulative noise by 42 Decibels relative to the Stage 4 guidelines. These goals apply to the integrated vehicle and propulsion system and are based on a reference mission of 3000nm flight of a Boeing 777-200 with GE90 engines. This paper will focus primarily on the ERA propulsion technology portfolio, which consists of advanced combustion, propulsor, and core technologies to enable these integrated air vehicle systems goals. An overview of the ERA propulsion technologies will be described and highlights of the results obtained during the first phase of ERA will be presented.
jet propulsion↗
Overview of the NASA Environmentally Responsible Aviation Project's Propulsion Technology Portfolio
The NASA Environmentally Responsible Aviation (ERA) Project is focused on developing and demonstrating integrated systems technologies to TRL 4-6 by 2020 that enable reduced fuel burn, emissions, and noise for futuristic air vehicles. The specific goals aim to simultaneously reduce fuel burn by 50%, reduce Landing and Take-off Nitrous Oxides emissions by 75% relative to the CAEP 6 guidelines, and reduce cumulative noise by 42 Decibels relative to the Stage 4 guidelines. These goals apply to the integrated vehicle and propulsion system and are based on a reference mission of 3000nm flight of a Boeing 777-200 with GE90 engines. This paper will focus primarily on the ERA propulsion technology portfolio, which consists of advanced combustion, propulsor, and core technologies to enable these integrated air vehicle systems goals. An overview of the ERA propulsion technologies will be described and the status and results to date will be presented.
aircraft engines↗
Results of an Advanced Fan Stage Operating Over a Wide Range of Speed and Bypass Ratio: Fan Stage Design and Experimental Results - Part 1
NASA s Fundamental Aeronautics Program is investigating turbine-based combined cycle (TBCC) propulsion systems for access to space because it provides the potential for aircraft-like, space-launch operations that may significantly reduce launch costs and improve safety. To this end, National Aeronautics and Space Administration (NASA) and General Electric (GE) teamed to design a Mach 4 variable cycle turbofan/ramjet engine for access to space. To enable the wide operating range of a Mach 4+ variable cycle turbofan ramjet required the development of a unique fan stage design capable of multi-point operation to accommodate variations in bypass ratio (10 ), fan speed (7 ), inlet mass flow (3.5 ), inlet pressure (8 ), and inlet temperature (3 ). In this paper, NASA has set out to characterize a TBCC engine fan stage aerodynamic performance and stability limits over a wide operating range including power-on and hypersonic-unique "windmill" operation. Herein, we will present the fan stage design, and the experimental test results of the fan stage operating from 15 to 100 percent corrected design speed. Whereas, in the companion paper, we will provide an assessment of NASA s APNASA code s ability to predict the fan stage performance and operability over a wide range of speed and bypass ratio.
Suder, Kenneth L.↗
Results of an Advanced Fan Stage Operating Over a Wide Range of Speed and Bypass Ratio: Comparison of CFD and Experimental Results - Part 2
NASA and GE teamed to design and build a 57 percent engine scaled fan stage for a Mach 4 variable cycle turbofan/ramjet engine for access to space with multipoint operations. This fan stage was tested in NASA's transonic compressor facility. The objectives of this test were to assess the aerodynamic and aero mechanic performance and operability characteristics of the fan stage over the entire range of engine operation including: 1) sea level static take-off; 2) transition over large swings in fan bypass ratio; 3) transition from turbofan to ramjet; and 4) fan wind-milling operation at high Mach flight conditions. This paper will focus on an assessment of APNASA, a multistage turbomachinery analysis code developed by NASA, to predict the fan stage performance and operability over a wide range of speeds (37 to 100 percent) and bypass ratios.
Celestina, Mark L.↗
An Overview of the NASA FAP Hypersonics Project Airbreathing Propulsion Research
The propulsion research portfolio of the National Aeronautics and Space Administration Fundamental Aeronautics Program Hypersonics Project encompasses a significant number of technical tasks that are aligned to achieve mastery and intellectual stewardship of the core competencies in the hypersonic-flight regime. An overall coordinated programmatic and technical effort has been structured to advance the state-of-the-art, via both experimental and analytical efforts. A subset of the entire hypersonics propulsion research portfolio is presented in this overview paper. To this end, two programmatic research disciplines are discussed; namely, (1) the Propulsion Discipline, including three associated research elements: the X-51A partnership, the HIFiRE-2 partnership, and the Durable Combustor Rig, and (2) the Turbine-Based Combine Cycle Discipline, including three associated research elements: the Combined Cycle Engine Large Scale Inlet Mode Transition Experiment, the small-scale Inlet Mode Transition Experiment, and the High-Mach Fan Rig.
Auslender, A. H.↗
TBCC Fan Stage Operability and Performance
NASA s Fundamental Aeronautics Program is investigating turbine-based propulsion systems for access to space because it provides the potential for aircraft-like, space-launch operations that may significantly reduce launch costs and improve safety. Studies performed under NASA s NGLT and the NASP High Speed Propulsion Assessment (HiSPA) program indicated a variable cycle turbofan/ramjet was the best configuration to satisfy access-to-space mission requirements because this configuration maximizes the engine thrust-to-weight ratio while minimizing frontal area. To this end, NASA and GE teamed to design a Mach 4 variable cycle turbofan/ramjet engine for access to space. To enable the wide operating range of a Mach 4+ variable cycle turbofan ramjet required the development of a unique fan stage design capable of multi-point operation to accommodate variations in bypass ratio (10X), fan speed (7X), inlet mass flow (3.5X), inlet pressure (8X), and inlet temperature (3X). The primary goal of the fan stage was to provide a high pressure ratio level with good efficiency at takeoff through the mid range of engine operation, while avoiding stall and losses at the higher flight Mach numbers, without the use of variable inlet guide vanes. Overall fan performance and operability therefore requires major consideration, as competing goals at different operating points and aeromechanical issues become major drivers in the design. To mitigate risk of meeting the unique design requirements for the fan stage, NASA and GE teamed to design and build a 57% engine scaled fan stage to be tested in NASA s transonic compressor facility. The objectives of this test are to assess the aerodynamic and aero mechanic performance and operability characteristics of the fan stage over the entire range of engine operation including: 1) sea level static take-off, 2) transition over large swings in fan bypass ratio, 3) transition from turbofan to ramjet, and 4) fan windmilling operation at high Mach flight conditions. In addition, the fan stage design was validated by performing pre-test CFD analysis using both GE proprietary and NASA s APNASA codes. Herein we will discuss 1) the fan stage design, 2) the experiment including the unique facility and instrumentation, and 3) the comparison of pre-test CFD analysis to initial aerodynamic test results for the baseline fan stage configuration. Measurements and pre-test analysis will be compared at 37%, 50%, 80%, 90%, and 100% of design speed to assess the ability of state-of-the-art design and analysis tools to meet the fan stage performance and operability requirements for turbine based propulsion for access to space.
Suder, Kenneth L.↗
Endwall Treatment and Method for Gas Turbine
An endwall treatment for a gas turbine engine having at least one rotor blade extending from a rotatable hub and a casing circumferentially surrounding the rotor and the hub, the endwall treatment including, an inlet formed in an endwall of the gas turbine engine adapted to ingest fluid from a region of a higher-pressure fluid, an outlet formed in the endwall and located in a region of lower pressure than the inlet, wherein the inlet and the outlet are in a fluid communication with each other, the outlet being adapted to inject the fluid from the inlet in the region of lower pressure, and wherein the outlet is at least partially circumferentially offset relative to the inlet.
Hathaway, Michael D.↗
The Effect of Variable Chord Length on Transonic Axial Rotor Performance
Aircraft fan and compressor blade leading edges suffer from atmospheric particulate erosion that reduces aerodynamic performance. Recontouring the blade leading edge region can restore blade performance. This process typically results in blades of varying chord length. The question therefore arises as to whether performance of refurbished fans and compressors could be further improved if blades of varying chord length are installed into the disk in a certain order. To investigate this issue the aerodynamic performance of a transonic compressor rotor operating with blades of varying chord length was measured in back-to-back compressor test rig entries. One half of the rotor blades were the full nominal chord length while the remaining half of the blades were cut back at the leading edge to 95% of chord length and recontoured. The rotor aerodynamic performance was measured at 100, 80, and 60% of design speed for three blade installation configurations: nominal-chord blades in half of the disk and short-chord blades in half of the disk; four alternating quadrants of nominal-chord and short-chord blades; nominal-chord and short-chord blades alternating around the disk. No significant difference in performance was found between configurations, indicating that blade chord variation is not important to aerodynamic performance above the stall chord limit if leading edges have the same shape. The stall chord limit for most civil aviation turbofan engines is between 94-96% of nominal (new) blade chord.
Roberts, William B.↗
Effect of Variable Chord Length on Transonic Axial Rotor Performance Investigated
During the life of any gas turbine, blade erosion is present, especially for those units that are exposed to unfiltered air, such as aviation turbofan engines. The effect of this erosion is to reduce the blade chord progressively from the midspan to the tip region and to roughen and distort the blade surface. The effects of roughness on rotor performance have been documented by Suder et al. and Roberts. These papers indicate that the penalty for leading-edge roughness and erosion can be significant. Turbofan operators, therefore, restore chord length at routine maintenance intervals to regain performance before deterioration is too severe to salvage blades. As the rotor blades erode, the leading edge becomes rough - blunt and distorted from the nominal shape - and the aerodynamic performance suffers. Nominal performance can be recovered by recontouring the leading edges. This process, which inherently shortens the blade chord, can be used until the blade chord erodes to the stall limit. Below this chord length, which varies among engine-compressor types, a decrease of stall margin is likely. After compressor blade rework that includes leading edge recontouring, the blades have different chord lengths, ranging from blades that are near nominal chord length down to those near the stall chord limit. Furthermore, as blades erode below the stall limit, they must be replaced with new blades that have the full nominal chord length. Consequently, a set of compressor blades with varying chord lengths will be installed into each turbofan engine that goes through a complete maintenance cycle. The question arises, "Does fan or compressor performance depend on the order in which mixed-chord blades are installed into a fan or compressor disk?"
Suder, Kenneth L.↗
Three-Dimensional Aerodynamic Instabilities In Multi-Stage Axial Compressors
This thesis presents the conceptualization and development of a computational model for describing three-dimensional non-linear disturbances associated with instability and inlet distortion in multistage compressors. Specifically, the model is aimed at simulating the non-linear aspects of short wavelength stall inception, part span stall cells, and compressor response to three-dimensional inlet distortions. The computed results demonstrated the first-of-a-kind capability for simulating short wavelength stall inception in multistage compressors. The adequacy of the model is demonstrated by its application to reproduce the following phenomena: (1) response of a compressor to a square-wave total pressure inlet distortion; (2) behavior of long wavelength small amplitude disturbances in compressors; (3) short wavelength stall inception in a multistage compressor and the occurrence of rotating stall inception on the negatively sloped portion of the compressor characteristic; (4) progressive stalling behavior in the first stage in a mismatched multistage compressor; (5) change of stall inception type (from modal to spike and vice versa) due to IGV stagger angle variation, and "unique rotor tip incidence" at these points where the compressor stalls through short wavelength disturbances. The model has been applied to determine the parametric dependence of instability inception behavior in terms of amplitude and spatial distribution of initial disturbance, and intra-blade-row gaps. It is found that reducing the inter-blade row gaps suppresses the growth of short wavelength disturbances. It is also concluded from these parametric investigations that each local component group (rotor and its two adjacent stators) has its own instability point (i.e. conditions at which disturbances are sustained) for short wavelength disturbances, with the instability point for the compressor set by the most unstable component group. For completeness, the methodology has been extended to describe finite amplitude disturbances in high-speed compressors. Results are presented for the response of a transonic compressor subjected to inlet distortions.
Tan, Choon S.↗
Active Control of Rotating Stall Demonstrated for a Multistage Compressor With Inlet Distortion
Aircraft compressors can suffer debilitating consequences as a result of rotating stall and surge events caused by inlet distortions. This is particularly true of aircraft during takeoff, when the compressor is operating at peak performance close to the surge line. Significant research has been conducted by the NASA Glenn Research Center in the area of compressor stability enhancement through active and passive control methods. Most recently, an experiment was conducted at the Wright Patterson Air Force Base Research Laboratory on a two-stage fan with inlet guide vanes and inlet distortion. In this joint Small Business Innovation Research effort between Scientific Systems and Glenn, control of rotating stall was demonstrated in a multistage transonic fan. This twostage fan with inlet guide vanes was tested under clean and distorted inlet conditions. The compressor was also configured with a circumferential distortion screen capable of 180 of distortion and with 14 high-velocity injectors upstream of the first rotor. Twelve of these injectors could oscillate up to frequencies of 450 Hz. The additional two injectors were located next to each other and were used in concert with each other as a single, on/off, high-authority actuator. In a first test of injection in this multistage environment, 12 of the valves were opened 50 percent of their full stroke to assess steady injection through the compressor. This baseline injection is shown in the compressor characteristic of the following figure, and stall margin improvements are tracked from this baseline condition. The compressor was then tested with clean inlet conditions using 12 injectors and active control. Pressure disturbances were tracked before rotating stall, and a constant gain control scheme reduced the stalling mass flow by 10.8 percent over the baseline. With the distortion screen present in the inlet, a pole-zero cancellation control scheme was used to achieve a 6.4-percent decrease in stalling mass flow. These improvements also are shown in the figure. In a final experiment, actively controlled, high-frequency injection from the 12 valves was used in conjunction with the high-authority actuators. In this test, the stalling mass flow of the compressor was reduced by 27 percent as indicated in the graph. These results were obtained by injecting less than 2 percent of the total compressor throughflow into the rotor tip region via 14 injection ports. These results mark the first successful demonstration of actively controlled air injection as a stall-control strategy for multistage compressors operating at speeds typical of an actual gas turbine engine. A goal of continuing research is to determine the combination of air-injection parameters and control strategies that are most effective in providing stall control for both clean and distorted inlet flow conditions for multistage environments. Other goals include the demonstration of stall control at many locations along the core compressor and development and application of active stall control strategies that will be integral flightworthy components of onboard engine hardware.
VanSchalkwyk, Christian↗
Compressor Stability Enhancement Using Discrete Tip Injection
Mass injection upstream of the tip of a high-speed axial compressor rotor is a stability enhancement approach known to be effective in suppressing small in tip-critical rotors. This process is examined in a transonic axial compressor rotor through experiments and time-averaged Navier-Stokes CFD simulations. Measurements and simulations for discrete injection are presented for a range of injection rates and distributions of injectors around the annulus. The simulations indicate that tip injection increases stability by unloading the rotor tip and that increasing injection velocity improves the effectiveness of tip injection. For the tested rotor, experimental results demonstrate that at 70 percent speed the stalling flow coefficient can be reduced by 30 percent using an injected mass- flow equivalent to 1 percent of the annulus flow. At design speed, the stalling flow coefficient was reduced by 6 percent using an injected mass-fiow equivalent to 2 percent of the annulus flow. The experiments show that stability enhancement is related to the mass-averaged axial velocity at the tip. For a given injected mass-flow, the mass-averaged axial velocity at the tip is increased by injecting flow over discrete portions of the circumference as opposed to full-annular injection. The implications of these results on the design of recirculating casing treatments and other methods to enhance stability will be discussed.
Suder, Kenneth L.↗
Experimental Investigation of the Flow Field in a Transonic, Axial Flow Compressor with Respect to the Development of Blockage and Loss
A detailed experimental investigation to understand and quantify the development of loss and blockage in the flow field of a transonic, axial flow compressor rotor has been undertaken. Detailed laser anemometer measurements were acquired upstream, within, and downstream of a transonic, axial compressor rotor operating at design and off-design conditions. The rotor was operated at 100%, 85%, 80%, and 60% of design speed which provided inlet relative Mach numbers at the blade tip of 1.48, 1.26, 1.18, and 0.89 respectively. At design speed the blockage is evaluated ahead of the rotor passage shock, downstream of the rotor passage shock, and near the trailing edge of the blade row. The blockage is evaluated in the core flow area as well as in the casing endwall region. Similarly at pm speed conditions for the cases of (1) where the rotor passage shock is much weaker than that at design speed and (2) where there is no rotor passage shock, the blockage and loss are evaluated and compared to the results at design speed. Specifically, the impact of the rotor passage shock on the blockage and loss development, pertaining to both the shock/boundary layer interactions and the shock/tip clearance flow interactions, is discussed. In addition, the blockage evaluated from the experimental data is compared to (1) an existing correlation of blockage development which was based on computational results, and (2) computational results on a limited basis. The results indicate that for this rotor the blockage in the endwall region is 2-3 times that of the core flow region and the blockage in the core flow region more than doubles when the shock strength is sufficient to separate the suction surface boundary layer. The distribution of losses in the care flow region indicate that the total loss is primarily comprised of the shock loss when the shock strength is not sufficient to separate the suction surface boundary layer. However, when the shock strength is sufficient to separate the suction surface boundary layer, the profile loss is comparable to the shock loss and can exceed the shock loss.
Suder, Kenneth L.↗
The effect of adding roughness and thickness to a transonic axial compressor rotor
The performance deterioration of a high speed axial compressor rotor due to surface roughness and airfoil thickness variations is reported. A 0.025 mm (0.001 in.) thick rough coating with a surface finish of 2.54-3.18 RMS microns (100-125 RMS microinches) is applied to the pressure and suction surface of the rotor blades. Coating both surfaces increases the leading edge thickness by 10% at the hub and 20% at the tip. Application of this coating results in a loss in efficiency of 6 points and a 9% reduction in the pressure ratio across the rotor at an operating condition near the design point. To separate the effect of thickness and roughness, a smooth coating of equal thickness is also applied to the blade. The smooth coating surface finish is 0.254-0.508 RMS microns (10-20 RMS microinches), compared to the bare metal blade surface finish of 0.508 RMS microns (20 RMS microinches). The smooth coating results in approximately half of the performance deterioration found from the rough coating. Both coatings are then applied to different portions of the blade surface to determine which portions of the airfoil are most sensitive to thickness/roughness variations. Aerodynamic performance measurements are presented for a number of coating configurations at 60%, 80%, and 100% of design speed. The results indicate that thickness/roughness over the first 10% of blade chord accounts for virtually all of the observed performance degradation for the smooth coating, compared to about 70% of the observed performance degradation for the rough coating. The performance deterioration is investigated in more detail at design speed using laser anemometer measurements as well as predictions generated by a quasi-3D Navier-Stokes flow solver which includes a surface roughness model. Measurements and analysis are performed on the baseline blade and the full-coverage smooth and rough coatings. The results indicate that coating the blade causes a thickening of the blade boundary layers. The interaction between the rotor passage shock and the thickened suction surface boundary layer then results in an increase in blockage which reduces the diffusion level in the rear half of the blade passage, thus reducing the aerodynamic performance of the rotor.
Suder, Kenneth L.↗