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NASA NTRS1985

Thermal barrier coatings for the space shuttle main engine turbine blades

The Space Shuttle Main Engine (SSME) turbopump turbine blades experience extremely severe thermal shocks during start-up and shut-down. For instance, the high pressure fuel turbopump turbine which burns liquid hydrogen operates at approximately 1500 F, but is shut down fuel rich with turbine blades quenced in liquid hydrogen. This thermal shock is a major contributor to blade cracking. The same thermal shock cause the protective ZrO2 thermal barrier coatings to spall or flake off, leaving only the NiCrAlY bond coating which provides only a minimum thermal protection. The turbine blades are therefore life limited to about 3000 sec for want of a good thermal barrier. A suitable thermal barrier coating (TBC) is being developed for the SSME turbine blades. Various TBCs developed for the gas turbine engines were tested in a specially built turbine blade tester. This tester subjects the coated blades to thermal and pressure cycles similar to those during actual operation of the turbine. The coatings were applied using a plasma spraying techniques both under atmospheric conditions and in vacuum. Results are presented. In general vacuum plasma sprayed coatings performed much better than those sprayed under atmospheric conditions. A 50 to 50 blend of Cr2O3 and NiCrAlY, vacuum plasma sprayed on SSME turbopump turbine blades appear to provide significant improvements in coating durability and thermal protection.

Bhat, B. N.↗

NASA NTRS1990

Wingtip vortex turbine investigation for vortex energy recovery

A flight test investigation has been conducted to determine the performance of wingtip vortex turbines and their effect on aircraft performance. The turbines were designed to recover part of the large energy loss (induced drag) caused by the wingtip vortex. The turbine, driven by the vortex flow, reduces the strength of the vortex, resulting in an associated induced drag reduction. A four-blade turbine was mounted on each wingtip of a single-engine, T-tail, general aviation airplane. Two sets of turbine blades were tested, one with a 15' twist (washin) and one with no twist. Th power recovered by the turbine and the installed drag increment were measured. A trade-off between turbine power and induced drag reduction was found to be a function of turbine blade incidence angle. This test has demonstrated that the wingtip vortex turbine is an attractive alternate, as well as an emergency, power source.

Abeyounis, William K.↗

NASA NTRS1954

Analytical investigation of off-design performance of a transonic turbine

The off-design performance and a breakdown of the losses of a transonic turbine were determined by an analytical method that was previously developed for turbines of more conservative design. The analytically obtained performance map is compared with the performance map obtained from an experimental investigation of the turbine. The rotor hub conditions of incidence angle, relative Mach number, and reaction calculated from the analytical results are compared with those calculated from experimental data. The loss breakdown obtained for the transonic turbine did not differ substantially from that previously obtained from a turbine of more conservative design, except that large stator-exit shock losses were predicted for the transonic turbine at low speeds. The trends of the rotor hub incidence angle, relative Mach number, and reaction calculated from the analytical results agreed well with those calculated from the experimental data over the performance range. These trends indicate that, compared with a turbine of more conservative design, the transonic turbine operated over a much smaller range of incidence angle, a much wider range of rotor relative Mach number, and at a considerably lower level of reaction. Good over-all agreement was obtained between the analytically predicted performance and the experimental performance, except at 40-percent design speed, where in the analysis the stator reached limiting loading before the rotor choked. Since this discrepancy resulted from errors in the simplifying assumptions used in the analysis, it is regarded as a limitation in the analytical method as applied to a transonic turbine.

Whitney, Warren J↗

NASA NTRS1958

Design and experimental investigation of a single-stage turbine with a rotor entering relative Mach number of 2

The design and experimental investigation of a single-stage supersonic turbine are presented herein. The turbine was designed for a rotor entering relative Mach number of 2. The maximum equivalent specific work output of the turbine at design speed and approximately design over-all pressure ratio was 32.9 BTU per pound at a static efficiency of 0.414. This static efficiency gave good verification to an independent reference that indicated theoretical static efficiencies for similar single-stage turbines within the range 0.40 to 0.45. An experimental ratio of effective rotor blade momentum thickness to mean camber length was determined to be 0.0014, which compares favorably with the results obtained from several transonic and subsonic turbines. The design procedure for this turbine would have been improved by allowing for more rotor losses by assuming a value of this momentum parameter comparable with those obtained from transonic turbines. Removing a large portion of the rotor suction surface enabled a lower static pressure to be felt at the stator exit, at the expense of higher rotor losses. The net result was an improvement in turbine work output of about 3 percent at design setting conditions. No problems associated with supersonic starting were encountered even under the worst conditions of turbine operation with respect to this problem.

Moffitt, Thomas P↗

NASA NTRS1994

Equations for Estimating the Strength of TV Signals Scattered by Wind Turbines

During the late 1970's and early 1980's, concerns about the potential interference of wind turbine generators with electromagnetic communication signals led to a series of research studies, both in the laboratory and in the field, conducted by the staff of the University of Michigan Radiation Laboratory. These studies were sponsored by organizations such as the U.S. Department of Energy, the Solar Energy Research Institute, and private developers of wind power stations. Research objectives were to identify the mechanisms by which wind turbines might adversely affect communication signals, estimate the severity of these effects for different types of signals (e.g. television, radio, microwave, and navigation), and formulate mathematical models with which to predict the sizes of potential interference zones around wind turbines and wind power plants. This work formed the basis for preliminary standards on assessing electromagnetic interference (EMI) by wind turbines. With the current renewal of interest in wind energy projects, it is appropriate that the many experimental and analytical aspects of this pioneering work be reviewed and correlated. The purpose of this study is to combine test data and theory from previously published and unpublished research reports into a unified and consistent set of equations which are useful for estimating potential levels of television interference from wind turbines. To be comprehensive, these equations will include both horizontal-axis and vertical-axis wind turbines (HAWT's and VAWT's), blade configuration parameters (e.g. number, size, material, twist, and coning), signal frequency and power, and directional characteristics of the receiving antenna. The approach that is followed in this report is as follows. First, some basic equations that describe electromagnetic signals with interference are presented without detailed derivations, since the latter are available in the references. Minor changes in terminology are made for purposes of consistency. Next, the concept of a signal scatter ratio is introduced, which defines the fraction of the signal impinging on a wind turbine that is scattered by its blades onto a nearby receiver. Equations from references are modified for the calculation of experimental scatter ratios (from measured signals containing interference) and idealized scatter ratios (from rotor characteristics and relative locations of the transmitter, the turbine, and the receiver). Experimental and idealized scatter ratios are then calculated and compared for 75 cases from the literature, in which TVI measurements were made around a variety of wind turbines. An empirical equation is then defined for estimating the probability that an actual scatter ratio will differ from an idealized ratio by a given amount. Finally a sample calculation of the size of a potential TV interference zone around a hypothetical wind power station is presented.

Spera, David A.↗

NASA NTRS2001

Unsteady Flow in a Supersonic Turbine with Variable Specific Heats

Modern high-work turbines can be compact, transonic, supersonic, counter-rotating, or use a dense drive gas. The vast majority of modern rocket turbine designs fall into these Categories. These turbines usually have large temperature variations across a given stage, and are characterized by large amounts of flow unsteadiness. The flow unsteadiness can have a major impact on the turbine performance and durability. For example, the Space Transportation Main Engine (STME) fuel turbine, a high work, transonic design, was found to have an unsteady inter-row shock which reduced efficiency by 2 points and increased dynamic loading by 24 percent. The Revolutionary Reusable Technology Turbopump (RRTT), which uses full flow oxygen for its drive gas, was found to shed vortices with such energy as to raise serious blade durability concerns. In both cases, the sources of the problems were uncovered (before turbopump testing) with the application of validated, unsteady computational fluid dynamics (CFD) to the designs. In the case of the RRTT and the Alternate Turbopump Development (ATD) turbines, the unsteady CFD codes have been used not just to identify problems, but to guide designs which mitigate problems due to unsteadiness. Using unsteady flow analyses as a part of the design process has led to turbine designs with higher performance (which affects temperature and mass flow rate) and fewer dynamics problems. One of the many assumptions made during the design and analysis of supersonic turbine stages is that the values of the specific heats are constant. In some analyses the value is based on an average of the expected upstream and downstream temperatures. In stages where the temperature can vary by 300 to 500 K, however, the assumption of constant fluid properties may lead to erroneous performance and durability predictions. In this study the suitability of assuming constant specific heats has been investigated by performing three-dimensional unsteady Navier-Stokes simulations for a supersonic turbine stage.

Dorney, Daniel J.↗

NASA NTRS2002

Rocket Engine Turbine Blade Surface Pressure Distributions Experiment and Computations

Understanding the unsteady aspects of turbine rotor flow fields is critical to successful future turbine designs. A technology program was conducted at NASA's Marshall Space Flight Center to increase the understanding of unsteady environments for rocket engine turbines. The experimental program involved instrumenting turbine rotor blades with miniature surface mounted high frequency response pressure transducers. The turbine model was then tested to measure the unsteady pressures on the rotor blades. The data obtained from the experimental program is unique in two respects. First, much more unsteady data was obtained (several minutes per set point) than has been possible in the past. Also, an extensive steady performance database existed for the turbine model. This allowed an evaluation of the effect of the on-blade instrumentation on the turbine's performance. A three-dimensional unsteady Navier-Stokes analysis was also used to blindly predict the unsteady flow field in the turbine at the design operating conditions and at +15 degrees relative incidence to the first-stage rotor. The predicted time-averaged and unsteady pressure distributions show good agreement with the experimental data. This unique data set, the lessons learned for acquiring this type of data, and the improvements made to the data analysis and prediction tools are contributing significantly to current Space Launch Initiative turbine airflow test and blade surface pressure prediction efforts.

Hudson, Susan T.↗

NASA NTRS2009

Preliminary Axial Flow Turbine Design and Off-Design Performance Analysis Methods for Rotary Wing Aircraft Engines: Applications - Part 2

In this paper, preliminary studies on two turbine engine applications relevant to the tilt-rotor rotary wing aircraft are performed. The first case-study is the application of variable pitch turbine for the turbine performance improvement when operating at a substantially lower shaft speed. The calculations are made on the 75 percent speed and the 50 percent speed of operations. Our results indicate that with the use of the variable pitch turbines, a nominal (3 percent (probable) to 5 percent (hypothetical)) efficiency improvement at the 75 percent speed, and a notable (6 percent (probable) to 12 percent (hypothetical)) efficiency improvement at the 50 percent speed, without sacrificing the turbine power productions, are achievable if the technical difficulty of turning the turbine vanes and blades can be circumvented. The second casestudy is the contingency turbine power generation for the tilt-rotor aircraft in the One Engine Inoperative (OEI) scenario. For this study, calculations are performed on two promising methods: throttle push and steam injection. By isolating the power turbine and limiting its air mass flow rate to be no more than the air flow intake of the take-off operation, while increasing the turbine inlet total temperature (simulating the throttle push) or increasing the air-steam mixture flow rate (simulating the steam injection condition), our results show that an amount of 30 to 45 percent extra power, to the nominal take-off power, can be generated by either of the two methods. The methods of approach, the results, and discussions of these studies are presented in this paper.

Chen, Shu-cheng, S.↗

NASA NTRS1947

Altitude-Wind-Tunnel Investigation of the 19B-2, 19B-8, and 19XB-1 Jet-Propulsion Engines. II - Analysis of Turbine Performance of the 19B-8 Engine

Performance characteristics of the turbine in the 19B-8 jet propulsion engine were determined from an investigation of the complete engine in the Cleveland altitude wind tunnel. The investigation covered a range of simulated altitudes from 5000 to 30,000 feet and flight Mach numbers from 0.05 to 0.46 for various tail-cone positions over the entire operable range of engine speeds. The characteristics of the turbine are presented as functions of the total-pressure ratio across the turbine and the turbine speed and the gas flow corrected to NACA standard atmospheric conditions at sea level. The effect of changes in altitude, flight Mach number, and tail-cone position on turbine performance is discussed. The turbine efficiency with the tail cone in varied from a maximum of 80.5 percent to minimum of 75 percent over a range of engine speeds from 7500 to 17,500 rpm at a flight Mach number of 0.055. Turbine efficiency was unaffected by changes in altitude up to 15,000 feet but was a function of tail-cone position and flight Mach number. Decreasing the tail-pipe-nozzle outlet area 21 percent reduced the turbine efficiency between 2 and 4.5 percent. The turbine efficiency increased between 1.5 and 3 percent as the flight Mach number changed from 0.055 to 0.297.

Krebs, Richard P.↗

NASA NTRS2010

Simulation of Turbine Tone Noise Generation Using a Turbomachinery Aerodynamics Solver

As turbofan engine bypass ratios continue to increase, the contribution of the turbine to the engine noise signature is receiving more attention. Understanding the relative importance of the various turbine noise generation mechanisms and the characteristics of the turbine acoustic transmission loss are essential ingredients in developing robust reduced-order models for predicting the turbine noise signature. A computationally based investigation has been undertaken to help guide the development of a turbine noise prediction capability that does not rely on empiricism. As proof-of-concept for this approach, two highly detailed numerical simulations of the unsteady flow field inside the first stage of a modern high-pressure turbine were carried out. The simulations were computed using TURBO, which is an unsteady Reynolds-Averaged Navier-Stokes code capable of multi-stage simulations. Spectral and modal analysis of the unsteady pressure data from the numerical simulation of the turbine stage show a circumferential modal distribution that is consistent with the Tyler-Sofrin rule. Within the high-pressure turbine, the interaction of velocity, pressure and temperature fluctuations with the downstream blade rows are all possible tone noise source mechanisms. We have taken the initial step in determining the source strength hierarchy by artificially reducing the level of temperature fluctuations in the turbine flowfield. This was accomplished by changing the vane cooling flow temperature in order to mitigate the vane thermal wake in the second of the two simulations. The results indicated that, despite a dramatic change in the vane cooling flow, the computed modal levels changed very little indicating that the contribution of temperature fluctuations to the overall pressure field is rather small compared with the viscous and potential field interaction mechanisms.

VanZante, Dale↗

NASA NTRS2019

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.↗

NASA NTRS1971

Analytical investigation of chord size and cooling methods on turbine blade cooling requirements. Book 1: Sections 1 through 8 and appendixes A through I

A study was conducted to determine the effect of chord size on air cooled turbine blades. In the preliminary design phase, eight turbine blade cooling configurations in 0.75-in., 1.0-in., and 1.5-in. chord sizes were analyzed to determine the maximum turbine inlet temperature capabilities. A pin fin convection cooled configuration and a film-impingement cooled configuration were selected for a final design analysis in which the maximum turbine inlet temperature was determined as a function of the cooling air inlet temperature and the turbine inlet total pressure for each of the three chord sizes. The cooling air flow requirements were also determined for a varying cooling air inlet temperature with a constant turbine inlet temperature. It was determined that allowable turbine inlet temperature increases with increasing chord for the convection cooled and transpiration cooled designs, however, the film-convection cooled designs did not have a significant change in turbine inlet temperature with chord.

Faulkner, F. E.↗

NASA NTRS1974

Highly loaded multi-stage fan drive turbine - performance of initial seven configurations

Experimental results of a three-stage highly loaded fan drive turbine test program are presented. A plain blade turbine, a tandem blade turbine, and a tangentially leaned stator turbine were designed for the same velocity diagram and flowpath. Seven combinations of bladerows were tested to evaluate stage performances and effects of the tandem blading and leaned stator. The plain blade turbine design point total-to-total efficiency was 0.886. The turbine with the stage three leaned stator had the same efficiency with an improved exit swirl profile and increased hub reaction. Two-stage group tests showed that the two-stage turbine with tandem stage two stator had an efficiency of 0.880 compared to 0.868 for the plain blade two-stage turbine.

Wolfmeyer, G. W.↗

NASA NTRS1976

Centaur boost pump turbine icing investigation

An investigation was conducted to determine if ice formation in the Centaur vehicle liquid oxygen boost pump turbine could prevent rotation of the pump and whether or not this phenomenon could have been the failure mechanism for the Titan/Centaur vehicle TC-1. The investigation consisted of a series of tests done in the LeRC Space Power Chamber Facility to evaluate evaporative cooling behavior patterns in a turbine as a function of the quantity of water trapped in the turbine and as a function of the vehicle ascent pressure profile. It was found that evaporative freezing of water in the turbine housing, due to rapid depressurization within the turbine during vehicle ascent, could result in the formation of ice that would block the turbine and prevent rotation of the boost pump. But for such icing conditions to exist it would be necessary to have significant quantities of water in the turbine and/or its components, and the turbine housing temperature would have to be colder than 40 F at vehicle liftoff.

Rollbuhler, R. J.↗

NASA NTRS1976

A review of the Mark 48-F, 3.50 pitch diameter, 2-stage reaction turbine designed for the staged combustion cycle requirements of an advanced space engine

The Mark 48-F two-stage reaction turbine was designed as a component for an advanced space engine propellant feed system, high-pressure liquid hydrogen turbopump. The turbine total inlet temperature and total inlet pressure were designed to be 1860 R and 3420 psia, respectively. At a design speed of 95,000 rpm, the turbine will develop 2543 horsepower with LO2/LH2 working fluid. The aerothermodynamic performance of a prototype turbine assembly was evaluated with gaseous nitrogen working fluid. Turbine performance was evaluated at turbine velocity ratios ranging from 0.250 to 0.782, and turbine speeds up to 25,250 rpm. Turbine test efficiency at the design velocity ratio of 0.483 was found to be 79.5% total-to-total.

Macaluso, S. B.↗

NASA NTRS1976

Two-phase turbine engines

A description is given of a two-phase turbine which utilizes a uniform mixture of gas and liquid accelerated in nozzles of the types reported by Elliott and Weinberg (1968). The mixture acts directly on an axial flow or tangential impulse turbine or is separated into gas and liquid streams which operate separately on a gas turbine and a hydraulic turbine. The basic two-phase cycles are examined, taking into account working fluids, aspects of nozzle expansion, details of turbine cycle operation, and the effect of mixture ratio variation. Attention is also given to two-phase nozzle efficiency, two-phase turbine operating characteristics and efficiencies, separator turbines, and impulse turbine experiments.

Elliott, D. G.↗

NASA NTRS1978

Effect of thermal barrier coatings on the performance of steam and water-cooled gas turbine/steam turbine combined cycle system

An analytical study was made of the performance of air, steam, and water-cooled gas-turbine/steam turbine combined-cycle systems with and without thermal-barrier coatings. For steam cooling, thermal barrier coatings permit an increase in the turbine inlet temperature from 1205 C (2200 F), resulting in an efficiency improvement of 1.9 percentage points. The maximum specific power improvement with thermal barriers is 32.4 percent, when the turbine inlet temperature is increased from 1425 C (2600 F) to 1675 C (3050 F) and the airfoil temperature is kept the same. For water cooling, the maximum efficiency improvement is 2.2 percentage points at a turbine inlet temperature of 1683 C (3062 F) and the maximum specific power improvement is 36.6 percent by increasing the turbine inlet temperature from 1425 C (2600 F) to 1730 C (3150 F) and keeping the airfoil temperatures the same. These improvements are greater than that obtained with combined cycles using air cooling at a turbine inlet temperature of 1205 C (2200 F). The large temperature differences across the thermal barriers at these high temperatures, however, indicate that thermal stresses may present obstacles to the use of coatings at high turbine inlet temperatures.

Nainiger, J. J.↗

NASA NTRS1984

Progress in the utilization of an oxide-dispersion-strengthened alloy for small engine turbine blades

The conventional means of improving gas turbine engine performance typically involves increasing the turbine inlet temperature; however, at these higher operational temperatures the high pressure turbine blades require air-cooling to maintain durability. Air-cooling imposes design, material, and economic constraints not only on the turbine blades but also on engine performance. The use of uncooled turbine blades at increased operating temperatures can offer significantly improved performance in small gas turbine engines. A program to demonstrate uncooled MA6000 high pressure turbine blades in a GTEC TFE731 turbofan engine is being conducted. The project goals include demonstration of the advantages of using uncooled MA6000 turbine blades as compared with cast directionally solidified MAR-M 247 blades.

Beatty, T. G.↗