SERT II - Durability of the hollow cathode and future applications of hollow cathodes
SERT 2 thrustor hollow cathode durability tested in bell jar
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SERT 2 thrustor hollow cathode durability tested in bell jar
A modified Hughes SIT-5 system is being tested for durability at the Lewis Research Center. As of October 1, 1972, the thruster subsystem has logged over 8000 hours of operation. The initial 2023 hours were run with a translating screen thrust vector grid. The thruster is currently operating with an electrostatic type vector grid. Profiles and maps taken at widely separated intervals show that performance and operating characteristics have remained essentially constant. Overall efficiency is about 32 percent and power to thrust ratio is 170 watts per millipound at a specific impulse of 2500 seconds. Telescopic examination of the vector grid shows some sputtering erosion due to charge exchange and direct impingement ions.
A 2000-hour durability test of a modified Hughes SIT-5 (Structurally Integrated Thruster, 5 cm) was conducted at the Lewis Research Center. The thruster operated with a translating screen thrust vector grid locked in position for 10 deg beam deflection. The test was essentially continuous except for seven stoppages of beam current. The neutralizer keeper voltage and thruster floating potential increased slightly with time. Performance profiles and maps of thruster characteristics were obtained at 453 and 2023 hours into the test. Overall efficiency was nearly constant at 31 - 32 percent, and operating characteristics were similar at both points in the test. A post-shutdown inspection showed negligible erosion damage to the accelerator and cathode baffle. Some erosion was found in the aperture of the neutralizer cathode.
A durability investigation was conducted on a group of eighteen bonded-wire strain gage pressure transducers with ranges of 0 to 15 psig and 0 to 100 psig using an improved version of a previously developed technique. Some of the transducers were subjected to 40 million pressure cycles at a 5-Hz rate at laboratory ambient conditions, others were cycled at a temperature of 150 F (65.6 C). The largest change in sensitivity observed was 0.22% for a 100-psig transducer subjected to 40 million pressure cycles at 150 F. The largest change in zero pressure output observed was 0.91% FS for the same transducer. None of the transducers failed completely as a result of cycling at or below full scale pressure.
A modified Hughes SIT-5 system is being tested for durability at the Lewis Research Center. As of Oct. 1, 1972, the thruster subsystem has logged over 8000 hours of operation. The initial 2023 hours were run with a translating screen thrust vector grid. The thruster is currently operating with an electrostatic type vector grid. Profiles and maps taken at widely separated intervals show that performance and operating characteristics have remained essentially constant. Overall efficiency is about 32 per cent and power to thrust ratio is 170 watts per millipound at a specific impulse of 2500 seconds. Telescopic examination of the vector grid shows some sputtering erosion due to charge exchange and direct impingement ions. An independent test of the propellant storage and cathode-isolator-vaporizer subsystem has demonstrated good reliability under simulated thruster operating conditions.
An improved design of air-atomizing fuel nozzles was determined from a study of four differently shaped splash-cone fuel nozzles after 56 hr of durability testing in a combustor segment. Test conditions included fuel-air ratios of 0.008 to 0.018, inlet-air total pressures of 41 to 203 N/cm, inlet-air temperatures of 477 to 811 K, and a reference velocity of 21.3 m/sec. Flat-tip fuel nozzles showed the least erosion damage and at a combustor operating condition of 700 K and 101 N/sq cm an oxides-of-nitrogen emission index of 12 and a smoke number of approximately 18 with a fuel-air ratio of 0.018. Emission indices for carbon monoxide and unburned hydrocarbons were 44 and 16, respectively, at simulated idle conditions of 477 K and 41 N/sq cm.
A report on the effects of fuel vortex film cooling on high temperature coating durability is presented. The program evaluated candidate high temperature oxidation resistant reaction control system engine thrust chamber material. As a result of the evaluation, the current and future programs may be optimized from the materials standpoint. Engine firing data for the evaluation of one material system is generated. The subjects considered are: (1) screening of materials, (2) thrust chamber fabrication, (3) engine testing, and (4) analysis of the data.
The durability of catalysts and catalyst supports in a combustion environment was experimentally demonstrated. A test of 1000 hours duration was completed with two catalysts, using diesel fuel and operating at catalytically supported thermal combustion conditions. The performance of the catalysts was determined by monitoring emissions throughout the test, and by examining the physical condition of the catalyst core at the conclusion of the test. The test catalysts proved to be capable of low emissions operation after 1000 hours diesel aging, with no apparent physical degradation of the catalyst support.
A durable antistatic coating is achieved on polymethylmethacrylate plastic without affecting its optical clarity by applying to the surface of the plastic a low molecular weight solvent having a high electron affinity and a high dipole moment, such as acentonitrile or nitromethane alone or in the presence of photopolymerizable monomer. The treated polymethylmethacrylate plastic dissipates most of the induced electrostatic charge and retains its optical clarity. The antistatic behavior persists after washing, rubbing and vacuum treatment.
A low temperature plasma polymerization process is described for applying an optical plastic substrate, such as a polymethyl methacrylate lens, with a single layer abrasive resistant coating to improve the durability of the plastic.
CODSTRAN (COmposite Durability STRuctural ANalysis) is an integrated computer program being developed for the prediction of defect growth and fracture of composite structures subjected to service loads and environments. CODSTRAN is briefly described with respect to organization, capabilities and present status. Application of CODSTRAN current capability to a flat composite laminate with a center slit which was subjected to axial tension loading predicted defect growth which is in good agreement with C-scan ultrasonic test records.
A two-year durability program was performed by AiResearch Phoenix to evaluate four commercially available ceramic materials under simulated automotive gas turbine combustor discharge conditions. These conditions included extended cyclic thermal exposures up to 2500 F and 3500 hr. The four materials selected for evaluation were Norton NCX-34 hot pressed silicon nitride, AiResearch RBN 101 reaction bonded silicon nitride, Carborundum pressureless sintered alpha-SiC and Pure Carbon Co. (British Nuclear Fuels, Ltd.) Refel reaction sintered silicon carbide. These materials were initially exposed to 350 hr/1750 cycles at 1200 and 1370 C. Subsequent exposures to 1050, 2100 and 3500 hr were performed on those materials maintaining 50% of baseline strength after the initial exposure. Additional evaluations of exposed bars included dimensional and weight changes, dye penetrant, specific damping capacity changes, SEM fractography, and X-ray diffraction.
The paper presents new information on the durability of a CATCOM catalyst operating at low-emission combustion temperatures (about 1527 K) with a liquid fuel, No. 2 diesel. Information on the activity of No. 2 diesel after 1000 hr of aging is given. In addition, a unique in situ activity test developed for monitoring the subtle changes in the catalyst activity of the CATCOM catalyst is also detailed. The study demonstrated the feasibility of using a CATCOM catalyst in catalytically supported thermal combustion for extended operating periods
An investigation is reported of improving the durability of plasma sprayed ceramic coatings for the vane platforms in the JT9d turbofan engine. The program aims for reduced fuel consumption of commercial aircraft engines; the use of improved strain tolerant microstructures and control of the substrate temperature during coating application are being evaluated. The initial burner rig tests at temperatures up to 1010 C indicated that improvements in cyclic life greater than 20:1 over previous ceramic coatings were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 1000-cycle JT9D engine endurance test with only minor damage occurring to the coatings.
A test facility for cyclic exposure of ceramic test bars to 1370 C has been designed as a means of the evaluation of the material durability under high-temperature cycling, particularly in heat-engine applications. The principal features of the test rig and test procedures are briefly discussed, and test results are presented for several commercial ceramics, including hot-pressed silicon nitride, carborundum sintered alpha-SiC, siliconized SiC, and reaction-bonded silicon nitride.
An 18 month combustor liner durability analysis program was conducted to evaluate the use of advanced three dimensional transient heat transfer and nonlinear stress-strain analyses for modeling the cyclic thermomechanical response of a simulated combustor liner specimen. Cyclic life prediction technology for creep/fatigue interaction is evaluated for a variety of state-of-the-art tools for crack initiation and propagation. The sensitivity of the initiation models to a change in the operating conditions is also assessed.
Included are fluid containment vessels, marine structures, and aircraft components with up to 19 years of service. Correlations were obtained for the variation of static fatigue strength, cyclic fatigue strength, and residual burst strength for pressure vessels. In addition, data are presented for the effects of moisture on strength retention. Data variations were analyzed, and relationships and implications for testing are discussed. Change in strength properties for complete structures was examined for indications of the effects of environmental conditions such as moisture and outdoor exposure (ultraviolet radiation, weathering) on long term durability.
Durability characteristics of current combustor liners severely limit liner life requirements of advanced gas turbine engines. This paper summarizes the development of a design which employed an advanced cooling technique and a segmented construction approach as a means to reduce cooling air and improve life through hoop stress reduction. Segmenting enables utilization of alloys with high temperature strength which offers a potential for a four-fold improvement in life relative to hoop construction with conventional materials. Fabrication techniques and results of tests conducted at high inlet pressure and temperature (P = 28 atm. and T = 811 K) are also presented.