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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Development of low Reynolds number two equation turbulence models for predicting external heat transfer on turbine blades

A research effort was underway to study the use of two equation low Reynolds number turbulence models in predicting gas side heat transfer on turbine blades. The major objectives of this work are basicly threefold: study the predictive capabilities of two equation low Reynolds number turbulence models under the conditions characteristic of modern gas turbine blades; explore potential improvements to the models themselves as well as to the specification of initial conditions; and provide a comparison of the predictions of these models with the experimental data from a broad range of recently available turbine cascade experiments. The problems associated with predicting the boundary layer transition from laminar to turbulent flow are emphasized, as this may be the most serious deficiency of current modeling techniques. The results and conclusions of the first two phases are briefly described.

Patankar, Suhas V.↗
NASA NTRS1995

Thermal and Structural Analysis of a Hollow Core Space Shuttle Main Engine (SSME) Turbine Blade

The influence of primary and secondary orientations on the elastic response of a hollow core, (001)-oriented nickel base single-crystal superalloy turbine blade, was investigated under combined thermal and mechanical conditions. Finite element techniques is employed through MARC finite element code to conduct the analyses on a hollow core SSME turbine blade made out of PWA 1480 single crystal material. Primary orientation of the single crystal superalloy was varied in increments of 2 deg, from 0 to 10 deg, from the (001) direction. Two secondary orientations (0 and 45 deg) were considered with respect to the global coordinate system, as the primary orientation angle was varied. The stresses developed within the single crystal blade were determined for different orientations of the blade. The influence of angular offsets such as the single crystal's primary and secondary orientations and the loading conditions on the elastic stress response of the PWA 1480 hollow blade are summarized. The influence of he primary orientation angle, when constrained between the bounds considered, was not found to be as significant as the influence of the secondary orientation angle.

Abdul-Aziz, Ali↗
NASA NTRSDate not supplied

LES Analysis of Loss Anomaly in a Turbine Blade with Large Trailing Edge Radius

There is great interest in the usage of Ceramic Matrix Composites (CMC) as a turbine blade material. CMCs can tolerate higher temperatures than alloyed metallic blades, resulting in better thermal efficiency of gas turbine engines. However, depending on the manufacturing process of the CMC, blades may have a larger trailing edge thickness. The design space therefore needs to be updated due to the resulting flow physics. Recently, experimental results acquired at NASA Glenn Transonic Turbine Blade Cascade Rig showed that a loss measure generally increased with increasing trailing edge thickness. For one case however, the losses initially decreased with increasing Reynolds number but rose and peaked at Re ~1.24x10 6 and then subsequently dropped to the original pre-peak trend. A possible cause of this intriguing phenomenon was speculated to be transonic vortex shedding, which is the mechanism of vortex shedding promoted by reflected shed pressure waves at the trailing edge at relatively high Reynolds numbers and higher Mach numbers. A Reynolds-averaged Navier-Stokes (RANS) analysis or a low-resolution large eddy simulation (LES) does not reproduce this apparent anomaly and thus it is worth performing a wall-resolved LES (the total mesh count of ~290 million cells) to investigate the aerodynamics of the CMC blade in the context of transonic vortex shedding. Our numerical results at Re=1,246,350 show that the pressure waves generated by the vortex shedding in the wake travel upstream and significantly influence the transition and separation on the suction side thus enhancing the said vortex shedding in the wake. This feedback seems not to hold under a low-Re condition (Re=621,900). The Reynolds number dependence was also examined by numerical perturbation of the pressure waves in the wake and by examining how such perturbation attenuates or endures. It is confirmed that the perturbation of the pressure waves is quickly damped.

LES↗
NASA NTRS2000

Effect of Crystal Orientation on Analysis of Single-Crystal, Nickel-Based Turbine Blade Superalloys

High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.

Swanson, G. R.↗
DOE OSTI2021

Validation of a lightning protection system for a fusion-welded thermoplastic composite wind turbine blade tip

Fusion welding for thermoplastic composite wind turbine blades is being investigated as a replacement for adhesives in bond lines to reduce manufacturing time and cost and to promote ease of recyclability. Resistance welding uses an electrically conductive material, such as carbon fiber, embedded in the bond line to heat the joining surfaces and fuse them together under pressure. One main challenge with fusion joining for large wind blades is the ability to use this conductive heating element in the bond line while still protecting the blade from the catastrophic effects of a lightning strike. This paper outlines the design and manufacturing of a lightning protection system for a 5-m-long thermally welded blade tip. The outcomes of high voltage and high current lightning testing applied to the 5 m blade tip show that the proposed design was able to protect the fusion welded bond lines from significant lightning damage.

17 WIND ENERGY↗
DOE OSTI2023

Automated Quantification of Wind Turbine Blade Leading Edge Erosion from Field Images

Wind turbine blade leading edge erosion is a major source of power production loss and early detection benefits optimization of repair strategies. Two machine learning (ML) models are developed and evaluated for automated quantification of the areal extent, morphology and nature (deep, shallow) of damage from field images. The supervised ML model employs convolutional neural networks (CNN) and learns features (specific types of damage) present in an annotated set of training images. The unsupervised approach aggregates pixel intensity thresholding with calculation of pixel-by-pixel shadow ratio (PTS) to independently identify features within images. The models are developed and tested using a dataset of 140 field images. The images sample across a range of blade orientation, aspect ratio, lighting and resolution. Each model (CNN v PTS) is applied to quantify the percent area of the visible blade that is damaged and classifies the damage into deep or shallow using only the images as input. Both models successfully identify approximately 65% of total damage area in the independent images, and both perform better at quantifying deep damage. The CNN is more successful at identifying shallow damage and exhibits better performance when applied to the images after they are preprocessed to a common blade orientation.

Aird, Jeanie A.↗
NASA NTRS1980

Nonlinear, three-dimensional finite-element analysis of air-cooled gas turbine blades

Cyclic stress-strain states in cooled turbine blades were calculated for a simulated mission of an advanced-technology commercial aircraft engine. The MARC, nonlinear, finite-element computer program was used for the analysis of impingement-cooled airfoils, with and without leading-edge film cooling. Creep was the predominant damage mode (ignoring hot corrosion), particularly artund film-cooling holes. Radially angled holes exhibited less creep than holes with axes normal to the surface. Beam-theory analyses of all-impingement-cooled airfoils gave fair agreement with MARC results for initial creep.

Kaufman, A.↗
NASA NTRS1980

Development of low-cost directionally-solidified turbine blades

A low-cost directionally solidified (DS) casting of turbine blades of high stress rupture is discussed. The process uses an exothermically heated mold; a newly designed solid blade was cast for the high-pressure turbine of the TFE731-3 turbofan engine. Ni-based alloys Mar-M 247 and Mar-M 200 + Hf were used. The solid DS blade replaced a conventionally cast IN100 component; a 40% cost saving is expected, with a 2.4% reduction in the takeoff specific fuel consumption. The DS Mar-M 247 blade has been selected for production in the TFE731-3B-100, and advanced version of the TFE731-3.

Hoppin, G. S., III↗
NASA NTRS2014

Aerodynamic Effects of High Turbulence Intensity on a Variable-Speed Power-Turbine Blade With Large Incidence and Reynolds Number Variations

The effects of high inlet turbulence intensity on the aerodynamic performance of a variable speed power turbine blade are examined over large incidence and Reynolds number ranges. These results are compared to previous measurements made in a low turbulence environment. Both high and low turbulence studies were conducted in the NASA Glenn Research Center Transonic Turbine Blade Cascade Facility. The purpose of the low inlet turbulence study was to examine the transitional flow effects that are anticipated at cruise Reynolds numbers. The current study extends this to LPT-relevant turbulence levels while perhaps sacrificing transitional flow effects. Assessing the effects of turbulence at these large incidence and Reynolds number variations complements the existing database. Downstream total pressure and exit angle data were acquired for 10 incidence angles ranging from +15.8deg to −51.0deg. For each incidence angle, data were obtained at five flow conditions with the exit Reynolds number ranging from 2.12×10(exp 5) to 2.12×10(exp 6) and at a design exit Mach number of 0.72. In order to achieve the lowest Reynolds number, the exit Mach number was reduced to 0.35 due to facility constraints. The inlet turbulence intensity, Tu, was measured using a single-wire hotwire located 0.415 axial-chord upstream of the blade row. The inlet turbulence levels ranged from 8 to 15 percent for the current study. Tu measurements were also made farther upstream so that turbulence decay rates could be calculated as needed for computational inlet boundary conditions. Downstream flow field measurements were obtained using a pneumatic five-hole pitch/yaw probe located in a survey plane 7 percent axial chord aft of the blade trailing edge and covering three blade passages. Blade and endwall static pressures were acquired for each flow condition as well. The blade loading data show that the suction surface separation that was evident at many of the low Tu conditions has been eliminated. At the extreme positive and negative incidence angles, the data show substantial differences in the exit flow field. These differences are attributable to both the higher inlet Tu directly and to the thinner inlet endwall boundary layer that the turbulence grid imposes.

Flegel, Ashlie B.↗
NASA NTRS2014

Aerodynamic Effects of High Turbulence Intensity on a Variable-Speed Power-Turbine Blade with Large Incidence and Reynolds Number Variations

The effects of high inlet turbulence intensity on the aerodynamic performance of a variable speed power turbine blade are examined over large incidence and Reynolds number ranges. These results are compared to previous measurements made in a low turbulence environment. Both high and low turbulence studies were conducted in the NASA Glenn Research Center Transonic Turbine Blade Cascade Facility. The purpose of the low inlet turbulence study was to examine the transitional flow effects that are anticipated at cruise Reynolds numbers. The current study extends this to LPT-relevant turbulence levels while perhaps sacrificing transitional flow effects. Assessing the effects of turbulence at these large incidence and Reynolds number variations complements the existing database. Downstream total pressure and exit angle data were acquired for 10 incidence angles ranging from +15.8deg to −51.0deg. For each incidence angle, data were obtained at five flow conditions with the exit Reynolds number ranging from 2.12×10(exp 5) to 2.12×10(exp 6) and at a design exit Mach number of 0.72. In order to achieve the lowest Reynolds number, the exit Mach number was reduced to 0.35 due to facility constraints. The inlet turbulence intensity, Tu, was measured using a single-wire hotwire located 0.415 axial-chord upstream of the blade row. The inlet turbulence levels ranged from 8 to 15 percent for the current study. Tu measurements were also made farther upstream so that turbulence decay rates could be calculated as needed for computational inlet boundary conditions. Downstream flow field measurements were obtained using a pneumatic five-hole pitch/yaw probe located in a survey plane 7 percent axial chord aft of the blade trailing edge and covering three blade passages. Blade and endwall static pressures were acquired for each flow condition as well. The blade loading data show that the suction surface separation that was evident at many of the low Tu conditions has been eliminated. At the extreme positive and negative incidence angles, the data show substantial differences in the exit flow field. These differences are attributable to both the higher inlet Tu directly and to the thinner inlet endwall boundary layer that the turbulence grid imposes.

Flegel, Ashlie B.↗
NASA NTRS1979

Large, low cost composite wind turbine blades

A woven roving E-glass tape, having all of its structural fibers oriented across the tape width was used in the manufacture of the spar for a wind turbine blade. Tests of a 150 ft composite blade show that the transverse filament tape is capable of meeting structural design requirements for wind turbine blades. Composite blades can be designed for interchangeability with steel blades in the MOD-1 wind generator system. The design, analysis, fabrication, and testing of the 150 ft blade are discussed.

Gewehr, H. W.↗
NASA NTRS1950

Analytical determination of local surface heat-transfer coefficients for cooled turbine blades from measured metal temperatures

Analytical methods are presented for the determination of local values of outside and inside heat-transfer coefficients and effective gas temperatures by use of turbine-blade-temperature measurements. The methods are derived for a number of configurations that can be applied to typical cooled-turbine-blade shapes as well as to other types of heat-transfer apparatus.

TURBINE COOLING↗
NASA NTRS1984

Low-cost single-crystal turbine blades, volume 2

The overall objectives of Project 3 were to develop the exothermic casting process to produce uncooled single-crystal (SC) HP turbine blades in MAR-M 247 and higher strength derivative alloys and to validate the materials process and components through extensive mechanical property testing, rig testing, and 200 hours of endurance engine testing. These Program objectives were achieved. The exothermic casting process was successfully developed into a low-cost nonproperietary method for producing single-crystal castings. Single-crystal MAR-M 247 and two derivatives DS alloys developed during this project, NASAIR 100 and SC Alloy 3, were fully characterized through mechanical property testing. SC MAR-M 247 shows no significant improvement in strength over directionally solidified (DS) MAR-M 247, but the derivative alloys, NASAIR 100 and Alloy 3, show significant tensile and fatigue improvements. Firtree testing, holography, and strain-gauge rig testing were used to determine the effects of the anisotropic characteristics of single-crystal materials. No undesirable characteristics were found. In general, the single-crystal material behaved similarly to DS MAR-M 247. Two complete engine sets of SC HP turbine blades were cast using the exothermic casting process and fully machined. These blades were successfully engine-tested.

Strangman, T. E.↗
DOE OSTI2023

The inclusion of uncertainty in circularity transition modeling: A case study on wind turbine blade end-of-life management

The transition to a more circular economy (CE) is complex and hard to predict, including in sustainable energy technologies. Many sources of uncertainty make it challenging to model CE scenarios and their potential benefits. As an example, the high variability in costs and revenues of different recycling options makes future wind turbine blade recycling highly uncertain. To better understand this challenge, the circular economy, life cycle assessment and visualization (CELAVI) framework - a discrete event simulation and life cycle assessment framework - is modified to incorporate uncertainty analysis capabilities. Moreover, a 3-step procedure that covers different aspects of uncertainty in CE studies and includes a Monte-Carlo analysis is proposed. The procedure is tested in a case study on wind turbine blade recycling using CELAVI. Results highlight that grinding and landfilling costs are the most influential parameters for wind power circularity. The model's output coefficients of variation (when input parameter uncertainties are propagated) are between 92% and 384% depending on the indicator. The approach developed in this study may help researchers and decision-makers who study circularity prioritize their data collection effort. Finally, our method contributes to a mounting yet critical body of research: the measurement of uncertainty in circularity transitions.

17 WIND ENERGY↗
NASA NTRS1987

A low-Reynolds-number two-equation turbulence model for predicting heat transfer on turbine blades

A modified form of the Lam-Bremhorst low-Reynolds number kappa-epsilon turbulence model was developed for predicting transitional boundary layer flows under conditions characteristic of gas turbine blades. The application of the model to flows with pressure gradients is described. Tests against a number of turbine blade cascade data sets are included. Some additional refinements of the model that were made in recent months are explained.

Patankar, Suhas V.↗
NASA NTRS1979

Evaluation of feasibility of prestressed concrete for use in wind turbine blades

A preliminary evaluation of the feasibility of the use of prestressed concrete as a material for low cost blades for wind turbines was conducted. A baseline blade design was achieved for an experimental wind turbine that met aerodynamic and structural requirements. Significant cost reductions were indicated for volume production. Casting of a model blade section showed no fabrication problems. Coupled dynamic analysis revealed that adverse rotor tower interactions can be significant with heavy rotor blades.

Leiblein, S.↗