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NASA NTRS1982

Nonlinear constitutive theory for turbine engine structural analysis

A number of viscoplastic constitutive theories and a conventional constitutive theory are evaluated and compared in their ability to predict nonlinear stress-strain behavior in gas turbine engine components at elevated temperatures. Specific application of these theories is directed towards the structural analysis of combustor liners undergoing transient, cyclic, thermomechanical load histories. The combustor liner material considered in this study is Hastelloy X. The material constants for each of the theories (as a function of temperature) are obtained from existing, published experimental data. The viscoplastic theories and a conventional theory are incorporated into a general purpose, nonlinear, finite element computer program. Several numerical examples of combustor liner structural analysis using these theories are given to demonstrate their capabilities. Based on the numerical stress-strain results, the theories are evaluated and compared.

Thompson, R. L.↗

DOE OSTI2026

Idealized Offshore Low‐Level Jets for Turbine Structural Impact Considerations

Low-level jets (LLJs) describe conditions in which the wind speed reaches a local maximum with respect to altitude near the surface; they have been observed intermittently in the US mid-Atlantic offshore environment. LLJs pose unique operating conditions for future wind turbines operating in the region, such as negative shear and locally strong veer, but they are not typically considered in existing turbine standards. This work builds upon recent research that explains the formation and evolution of the US mid-Atlantic LLJs through a simple analytical governing equation. We generate several LLJ inflow conditions with varying jet characteristics based on this analytical model and create monotonically sheared (MS) analogues with matched veer to assess the impacts of the LLJ on turbine performance and loading. Using aeroelastic simulations with these inflow conditions on the International Energy Agency 15-MW reference turbine, we find that the LLJ leads to a greater range of tower-top pitching and yawing moments, which could contribute to larger accumulated structural fatigue in components compared to MS inflow. These preliminary results demonstrate a path toward a unified set of test cases for low-level wind maxima that can inform the International Electrotechnical Commission standards related to offshore wind turbine design.

17 WIND ENERGY↗

NASA NTRS1982

Environmental and high strain rate effects on composites for engine applications

The complex environmental and loading conditions experienced by many turbine engine components impose severe durability and damage tolerance requirements for component materials. Programs are being conducted to establish the structural performance of composite materials under anticipated engine operating environments. A description is presented of the results obtained in connection with several of these programs. A comparison of predicted and measured hygrothermal effects is considered along with hygrothermal effects on defect growth, high strain rate effects on composite mechanical properties, dynamic stress intensity factors for composites, and the indentation laws for composite impact analysis.

Chamis, C. C.↗

NASA NTRS1984

The 3-D inelastic analysis methods for hot section components (base program)

A series of computer codes are sought that would permit more accurate and efficient three-dimensional inelastic structural analysis of combustor liners, turbine blades, and turbine vanes. Each code embodies a progression of mathematical models for increasingly comprehensive representation of the geometrical features, loading conditions, and forms of nonlinear material response that distinguish these three groups of hot section components.

Todd, E. S.↗

NASA NTRS1985

3-D inelastic analysis methods for hot section components

The objective is to produce a series of new computer codes that permit more accurate and efficient three dimensional inelastic structural analysis of combustor liners, turbine blades, and turbine vanes. Each code embodies a progression of mathematical models for increasingly comprehensive representaion of the geometrical features, loading conditions, and forms of nonlinear material response that distinguish these three groups of hot section components.

Todd, E. S.↗

NASA NTRS1986

On 3-D inelastic analysis methods for hot section components

The objective of this program is to produce a series of new computer codes that permit more accurate and efficient three-dimensional inelastic structural analysis of combustor liners, turbine blades, and turbine vanes. Each code embodies a progression of mathematical models for increasingly comprehensive representation of the geometrical features, loading conditions, and forms of nonlinear material response that distinguish these three groups of hot section components.

Todd, E. S.↗

NASA NTRS1987

Three-dimensional inelastic analysis methods for hot section components

Todd, E. S.↗

NASA NTRS2011

Comprehensive Forced Response Analysis of J2X Turbine Bladed-Discs with 360 Degree Variation in CFD Loading

The temporal frequency content of the dynamic pressure predicted by a 360 degree computational fluid dynamics (CFD) analysis of a turbine flow field provides indicators of forcing function excitation frequencies (e.g., multiples of blade pass frequency) for turbine components. For the Pratt and Whitney Rocketdyne J-2X engine turbopumps, Campbell diagrams generated using these forcing function frequencies and the results of NASTRAN modal analyses show a number of components with modes in the engine operating range. As a consequence, forced response and static analyses are required for the prediction of combined stress, high cycle fatigue safety factors (HCFSF). Cyclically symmetric structural models have been used to analyze turbine vane and blade rows, not only in modal analyses, but also in forced response and static analyses. Due to the tortuous flow pattern in the turbine, dynamic pressure loading is not cyclically symmetric. Furthermore, CFD analyses predict dynamic pressure waves caused by adjacent and non-adjacent blade/vane rows upstream and downstream of the row analyzed. A MATLAB script has been written to calculate displacements due to the complex cyclically asymmetric dynamic pressure components predicted by CFD analysis, for all grids in a blade/vane row, at a chosen turbopump running speed. The MATLAB displacements are then read into NASTRAN, and dynamic stresses are calculated, including an adjustment for possible mistuning. In a cyclically symmetric NASTRAN static analysis, static stresses due to centrifugal, thermal, and pressure loading at the mode running speed are calculated. MATLAB is used to generate the HCFSF at each grid in the blade/vane row. When compared to an approach assuming cyclic symmetry in the dynamic flow field, the current approach provides better assurance that the worst case safety factor has been identified. An extended example for a J-2X turbopump component is provided.

Elrod, David↗

NASA NTRS1981

Acoustic noise generation by the DOE/NASA MOD-1 wind turbine

The results of a series of measurements taken over the past year of the acoustic emissions from the DOE/NASA MOD-1 Wind Turbine show the maximum acoustic energy is concentrated in the low frequency range, often below 100 Hz. The temporal as well as the frequency characteristics of the turbine sounds have been shown to be important since the MOD-1 is capable of radiating both coherent and incoherent noise. The coherent sounds are usually impulsive and are manifested in an averaged frequency domain plot as large numbers of discrete energy bands extending from the blade passage frequency to beyond 50 Hz on occasion. It is these impulsive sounds which are identified as the principal source of the annoyance to a dozen families living within 3 km of the turbine. The source of the coherent noise appears to be the rapid, unsteady blade loads encountered as the blade passes through the wake of the tower structure. Annoying levels are occasionally reached at nearby homes due to the interaction of the low frequency, high energy peaks in the acoustic impulses and the structural modes of the homes as well as by direct radiation outdoors. The peak levels of these impulses can be enhanced or subdued through complete propagation.

Kelley, N. D.↗

DOE OSTI2020

Implementation of Substructure Flexibility and Member-Level Load Capabilities for Floating Offshore Wind Turbines in OpenFAST

OpenFAST is an open-source, physics-based engineering tool applicable to the load analysis of land-based and offshore wind turbines, including floating offshore wind turbines. The substructure for a floating wind turbine has historically been modeled in OpenFAST as a rigid body with hydrodynamic loads lumped at a point, which enabled the tool to predict the global response of the floating substructure but not the structural loads within its individual members. This limitation is an impediment to designing floating substructures - especially newer designs that are more streamlined, flexible, and cost-effective. This paper presents the development of new functionality in OpenFAST to model floating substructure flexibility and member-level loads, as well as the concepts and mathematical background needed to understand and apply it correctly.

17 WIND ENERGY↗

DOE OSTI2019

Substructure Flexibility and Member-Level Load Capabilities for Floating Offshore Wind Turbines in OpenFAST

OpenFAST is an open-source, physics-based engineering tool applicable to the load analysis of land-based and offshore wind turbines, including floating offshore wind turbines. The substructure for a floating wind turbine has historically been modeled in OpenFAST as a rigid body with hydrodynamic loads lumped at a point, which enabled the tool to predict the global response of the floating substructure but not the structural loads within its individual members. This limitation is an impediment to designing floating substructures - especially newer designs that are more streamlined, flexible, and cost-effective. This paper presents the development plan of new capabilities in OpenFAST to model floating substructure flexibility and member-level loads, including the functional requirements and modeling approaches needed to understand and apply them correctly.

17 WIND ENERGY↗

NASA NTRS1983

Advanced Gas Turbine (AGT) technology development

A 74.5 kW (100 hp) automotive gas turbine was evaluated. The engine structure, bearings, oil system, and electronics were demonstrated and no shaft dynamics or other vibration problem were encountered. Areas identified during the five tests are the scroll retention features, and transient thermal deflection of turbine backplates. Modifications were designed. Seroll retention is addressed by modifying the seal arrangement in front of the gasifier turbine assembly, which will increase the pressure load on the scroll in the forward direction and thereby increase the retention forces. the backplate thermal deflection is addressed by geometric changes and thermal insulation to reduce heat input. Combustor rig proof testing of two ceramic combustor assemblies was completed. The combustor was modified to incorporate slots and reduce sharp edges, which should reduce thermal stresses. The development work focused on techniques to sinter these barrier materials onto the ceramic rotors with successes for both material systems. Silicon carbide structural parts, including engine configuration gasifier rotors (ECRs), preliminary gasifier scroll parts, and gasifier and power turbine vanes are fabricated.

Source record↗

NASA NTRS2012

Turbine Engine Disk Rotor Health Monitoring Assessment Using Spin Tests Data

Detecting rotating engine component malfunctions and structural anomalies is increasingly becoming a crucial key feature that will help boost safety and lower maintenance cost. However, achievement of such technology, which can be referred to as a health monitoring remains somewhat challenging to implement. This is mostly due to presence of scattered loading conditions, crack sizes, component geometry and material properties that hinders the simplicity of imposing such application. Different approaches are being considered to assist in developing other means of health monitoring or nondestructive techniques to detect hidden flaws and mini cracks before any catastrophic events occur. These methods extend further to assess material discontinuities and other defects that have matured to the level where a failure is very likely. This paper is focused on presenting data obtained from spin test experiments of a turbine engine like rotor disk and their correlation to the development of a structural health monitoring and fault detection system. The data collected includes blade tip clearance, blade tip timing measurements and shaft displacements. The experimental results are collected at rotational speeds up to 10,000 Rpm and tests are conducted at the NASA Glenn Research Center s Rotordynamics Laboratory via a high precision spin system. Additionally, this study offers a closer glance at a selective online evaluation of a rotating disk using advanced capacitive, microwave and eddy current sensor technology.

Abdul-Aziz, Ali↗

NASA NTRS1982

A 400-kWe high-efficiency steam turbine for industrial cogeneration

An advanced state-of-the-art steam turbine-generator developed to serve as the power conversion subsystem for the Department of Energy's Sandia National Laboratories' Solar Total-Energy Project (STEP) is described. The turbine-generator, which is designed to provide 400-kW of net electrical power, represents the largest turbine-generator built specifically for commercial solar-powered cogeneration. The controls for the turbine-generator incorporate a multiple, partial-arc entry to provide efficient off-design performance, as well as an extraction control scheme to permit extraction flow regulation while maintaining 110-spsig pressure. Normal turbine operation is achieved while synchronized to a local utility and in a stand-alone mode. In both cases, the turbine-generator features automatic load control as well as remote start-up and shutdown capability. Tests totaling 200 hours were conducted to confirm the integrity of the turbine's mechanical structure and control function. Performance tests resulted in a measured inlet throttle flow of 8,450 pounds per hour, which was near design conditions.

Leibowitz, H. M.↗

NASA NTRS1985

Development and testing of tip devices for horizontal axis wind turbines

A theoretical and field experimental program has been carried out to investigate the use of tip devices on horizontal axis wind turbine rotors. The objective was to improve performance by the reduction of tip losses. While power output can always be increased by a simple radial tip extension, such a modification also results in an increased gale load both because of the extra projected area and longer moment arm. Tip devices have the potential to increase power output without such a structural penalty. A vortex lattice computer model was used to optimize three basic tip configuration types for a 25 kW stall limited commercial wind turbine. The types were a change in tip planform, and a single-element and double-element nonplanar tip extension (winglets). A complete data acquisition system was developed which recorded three wind speed components, ambient pressure, temperature, and turbine output. The system operated unattended and could perform real-time processing of the data, displaying the measured power curve as data accumulated in either a bin sort mode or polynomial curve fit. Approximately 270 hr of perormance data were collected over a three-month period. The sampling interval was 2.4 sec; thrus over 400,000 raw data points were logged. Results for each of the three new tip devices, compared with the original tip, showed a small decrease (of the order of 1 kW) in power output over the measured range of wind speeds from cut-in at about 4 m/s to over 20 m/s, well into the stall limiting region. Changes in orientation and angle-of-attack of the winglets were not made. For aircraft wing tip devices, favorable tip shapes have been reported and it is likely that the tip devices tested in this program did not improve rotor performance because they were not optimally adjusted.

Gyatt, G. W.↗

NASA NTRS1950

Range Performance of Bombers Powered by Turbine-Propeller Power Plants

Calculations have been made to find range? attainable by bombers of gross weights from l40,000 to 300,000 pounds powered by turbine-propeller power plants. Only conventional configurations were considered and emphasis was placed upon using data for structural and aerodynamic characteristics which are typical of modern military airplanes. An effort was made to limit the various parameters invoked in the airplane configuration to practical values. Therefore, extremely high wing loadings, large amounts of sweepback, and very high aspect ratios have not been considered. Power-plant performance was based upon the performance of a typical turbine-propeller engine equipped with propellers designed to maintain high efficiencies at high-subsonic speeds. Results indicated, in general, that the greatest range, for a given gross weight, is obtained by airplanes of high wing loading, unless the higher cruising speeds associated with the high-wing-loading airplanes require-the use of thinner wing sections. Further results showed the effect of cruising at-high speeds, of operation at very high altitudes, and of carrying large bomb loads.

Cline, Charles W.↗

NASA NTRS1981

Guy cable design and damping for vertical axis wind turbines

Guy cables are frequently used to support vertical axis wind turbines since guying the turbine reduces some of the structural requirements on the tower. The guys must be designed to provide both the required strength and the required stiffness at the top of the turbine. The axial load which the guys apply to the tower, bearings, and foundations is an undesirable consequence of using guys to support the turbine. Limiting the axial load so that it does not significantly affect the cost of the turbine is an important objective of the cable design. The lateral vibrations of the cables is another feature of the cable design which needs to be considered. These aspects of the cable design are discussed, and a technique for damping cable vibrations was mathematically analyzed and demonstrated with experimental data.

Carne, T. G.↗

NASA NTRS1991

Localization of aeroelastic modes in mistuned high-energy turbines

The effects of blade mistuning on the aerodynamic characteristics of a class of bladed-disk assemblies, namely high energy turbines, are discussed. The specific rotor analyzed is the first stage of turbine blades of the oxidizer turbopump in the Space Shuttle Main Engine. The common occurrence of fatigue cracks for these turbine blades indicates the possibility of high dynamic loading. Since mistuning under conditions of weak interblade coupling has been shown to increase blade response amplitudes drastically for simple structural models of blade assemblies, it provides a plausible explanation for the occurrence of cracks. The focus here is on the effects of frequency mistuning on the aeroelastic stability of the assembly and on the aeroelastic mode shapes.

Smith, Todd E.↗