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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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NASA NTRS1992

An efficient HZETRN (a galactic cosmic ray transport code)

An accurate and efficient engineering code for analyzing the shielding requirements against the high-energy galactic heavy ions is needed. The HZETRN is a deterministic code developed at Langley Research Center that is constantly under improvement both in physics and numerical computation and is targeted for such use. One problem area connected with the space-marching technique used in this code is the propagation of the local truncation error. By improving the numerical algorithms for interpolation, integration, and grid distribution formula, the efficiency of the code is increased by a factor of eight as the number of energy grid points is reduced. The numerical accuracy of better than 2 percent for a shield thickness of 150 g/cm(exp 2) is found when a 45 point energy grid is used. The propagating step size, which is related to the perturbation theory, is also reevaluated.

Shinn, Judy L.↗

NASA NTRS2004

Development of Advanced Low Conductivity Thermal Barrier Coatings

Advanced multi-component, low conductivity oxide thermal barrier coatings have been developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and electron beam-physical vapor deposited (EB-PVD) thermal barrier coatings under the NASA Ultra-Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities and improved thermal stability due to an oxide-defect-cluster design. Critical issues for designing advanced low conductivity coatings with improved coating durability are also discussed.

Zhu, Dong-Ming↗

NASA NTRS2014

Design Optimization of a Variable-Speed Power Turbine

NASA's Rotary Wing Project is investigating technologies that will enable the development of revolutionary civil tilt rotor aircraft. Previous studies have shown that for large tilt rotor aircraft to be viable, the rotor speeds need to be slowed significantly during the cruise portion of the flight. This requirement to slow the rotors during cruise presents an interesting challenge to the propulsion system designer as efficient engine performance must be achieved at two drastically different operating conditions. One potential solution to this challenge is to use a transmission with multiple gear ratios and shift to the appropriate ratio during flight. This solution will require a large transmission that is likely to be maintenance intensive and will require a complex shifting procedure to maintain power to the rotors at all times. An alternative solution is to use a fixed gear ratio transmission and require the power turbine to operate efficiently over the entire speed range. This concept is referred to as a variable-speed power-turbine (VSPT) and is the focus of the current study. This paper explores the design of a variable speed power turbine for civil tilt rotor applications using design optimization techniques applied to NASA's new meanline tool, the Object-Oriented Turbomachinery Analysis Code (OTAC).

design optimization↗

NASA NTRS2016

Integrated Turbine Tip Clearance and Gas Turbine Engine Simulation

Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.

aerothermodynamics↗

NASA NTRS2016

Integrated Turbine Tip Clearance and Gas Turbine Engine Simulation

gas path dynamics↗

NASA NTRS2005

Innovative Adaptive Control Method Demonstrated for Active Suppression of Instabilities in Engine Combustors

This year, an improved adaptive-feedback control method was demonstrated that suppresses thermoacoustic instabilities in a liquid-fueled combustor of a type used in aircraft engines. Extensive research has been done to develop lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle to reduce the environmental impact of aerospace propulsion systems. However, these lean-burning combustors are susceptible to thermoacoustic instabilities (high-frequency pressure waves), which can fatigue combustor components and even downstream turbine blades. This can significantly decrease the safe operating life of the combustor and turbine. Thus, suppressing the thermoacoustic combustor instabilities is an enabling technology for meeting the low-emission goals of the NASA Ultra-Efficient Engine Technology (UEET) Project.

Kopasakis, George↗

NASA NTRS1994

(abstract) Design and Testing of a Fullerene RF Ion Engine

Because of the large mass, low ionization potential and large electron impact ionization cross section, use of buckminsterfullerene (C 60 ) as a propellant might result in significant increases in ion engine efficiency over that obtained with xenon at low specific impulse. Consequently, an experimantal program to investigate the feasibility of using fullerenes as a propellant was initiated. To eliminate the possibility of hot cathode surfaces causing fragmentation, fabrication of a radio-frequency discharge chamber was pursued. Experimental results using the radio-frequency source will be presented.

fullerenes↗

NASA NTRS2004

Melt-infiltrated Sic Composites for Gas Turbine Engine Applications

SiC-SiC ceramic matrix composites (CMCs) manufactured by the slurry -cast melt-infiltration (MI) process are leading candidates for many hot-section turbine engine components. A collaborative program between Goodrich Corporation and NASA-Glenn Research Center is aimed at determining and optimizing woven SiC/SiC CMC performance and reliability. A variety of composites with different fiber types, interphases and matrix compositions have been fabricated and evaluated. Particular focus of this program is on the development of interphase systems that will result in improved intermediate temperature stressed-oxidation properties of this composite system. The effect of the different composite variations on composite properties is discussed and, where appropriate, comparisons made to properties that have been generated under NASA's Ultra Efficient Engine Technology (UEET) Program.

Morscher, Gregory N.↗

NASA NTRS2002

Dual Microstructure Heat Treatment of a Nickel-Base Disk Alloy Assessed

Gas turbine engines for future subsonic aircraft will require nickel-base disk alloys that can be used at temperatures in excess of 1300 F. Smaller turbine engines, with higher rotational speeds, also require disk alloys with high strength. To address these challenges, NASA funded a series of disk programs in the 1990's. Under these initiatives, Honeywell and Allison focused their attention on Alloy 10, a high-strength, nickel-base disk alloy developed by Honeywell for application in the small turbine engines used in regional jet aircraft. Since tensile, creep, and fatigue properties are strongly influenced by alloy grain size, the effect of heat treatment on grain size and the attendant properties were studied in detail. It was observed that a fine grain microstructure offered the best tensile and fatigue properties, whereas a coarse grain microstructure offered the best creep resistance at high temperatures. Therefore, a disk with a dual microstructure, consisting of a fine-grained bore and a coarse-grained rim, should have a high potential for optimal performance. Under NASA's Ultra-Safe Propulsion Project and Ultra-Efficient Engine Technology (UEET) Program, a disk program was initiated at the NASA Glenn Research Center to assess the feasibility of using Alloy 10 to produce a dual-microstructure disk. The objectives of this program were twofold. First, existing dual-microstructure heat treatment (DMHT) technology would be applied and refined as necessary for Alloy 10 to yield the desired grain structure in full-scale forgings appropriate for use in regional gas turbine engines. Second, key mechanical properties from the bore and rim of a DMHT Alloy 10 disk would be measured and compared with conventional heat treatments to assess the benefits of DMHT technology. At Wyman Gordon and Honeywell, an active-cooling DMHT process was used to convert four full-scale Alloy 10 disks to a dual-grain microstructure. The resulting microstructures are illustrated in the photomicrographs. The fine grain size in the bore can be contrasted with the coarse grain size in the rim. Testing (at NASA Glenn) of coupons machined from these disks showed that the DMHT approach did indeed produce a high-strength, fatigue resistant bore and a creep-resistant rim. This combination of properties was previously unobtainable using conventional heat treatments, which produced disks with a uniform grain size. Future plans are in place to spin test a DMHT disk under the Ultra Safe Propulsion Project to assess the viability of this technology at the component level. This testing will include measurements of disk growth at a high temperature as well as the determination of burst speed at an intermediate temperature.

Gayda, John↗

NASA NTRS2002

Ceramic Composite Intermediate Temperature Stress-Rupture Properties Improved Significantly

Silicon carbide (SiC) composites are considered to be potential materials for future aircraft engine parts such as combustor liners. It is envisioned that on the hot side (inner surface) of the combustor liner, composites will have to withstand temperatures in excess of 1200 C for thousands of hours in oxidizing environments. This is a severe condition; however, an equally severe, if not more detrimental, condition exists on the cold side (outer surface) of the combustor liner. Here, the temperatures are expected to be on the order of 800 to 1000 C under high tensile stress because of thermal gradients and attachment of the combustor liner to the engine frame (the hot side will be under compressive stress, a less severe stress-state for ceramics). Since these composites are not oxides, they oxidize. The worst form of oxidation for strength reduction occurs at these intermediate temperatures, where the boron nitride (BN) interphase oxidizes first, which causes the formation of a glass layer that strongly bonds the fibers to the matrix. When the fibers strongly bond to the matrix or to one another, the composite loses toughness and strength and becomes brittle. To increase the intermediate temperature stress-rupture properties, researchers must modify the BN interphase. With the support of the Ultra-Efficient Engine Technology (UEET) Program, significant improvements were made as state-of-the-art SiC/SiC composites were developed during the Enabling Propulsion Materials (EPM) program. Three approaches were found to improve the intermediate-temperature stress-rupture properties: fiber-spreading, high-temperature silicon- (Si) doped boron nitride (BN), and outside-debonding BN.

Morscher, Gregory N.↗

NASA NTRS1988

Materials and structures for hypersonic vehicles

The development of low-density materials with higher strength and stiffness, and more efficient engine and airframe structures is considered enabling technology for reusable hypersonic vehicles. Advanced structural concepts are required for minimum weight hot structures that will be fully reusable. Key design drivers are maximum heating rate, duration of heating, total heat load, flight envelope and type of propulsion system, mission life requirements, and containment of liquid hydrogen. For hot-structures applications in the range from 600-1800°F, advanced alloys of titanium, titanium and nickel aluminides, and metal-matrix composites are leading candidates because of their high specific properties. For temperatures in excess of 2000°F carbon-carbon and ceramic-matrix composites are the most structurally efficient materials. This paper addresses the technology issues for light weight hot structures, gives brief assessments of the state of the art, presents selected highlights of current research, and identifies areas requiring additional development.

Hypersonic Vehicles↗

NASA NTRS1989

Materials and structures for hypersonic vehicles

Hypersonic Vehicles↗

NASA NTRS2002

Innovative Airbreathing Propulsion Concepts for High-speed Applications

The current cost to launch payloads to low earth orbit (LEO) is approximately loo00 U.S. dollars ($) per pound ($22000 per kilogram). This high cost limits our ability to pursue space science and hinders the development of new markets and a productive space enterprise. This enterprise includes NASA's space launch needs and those of industry, universities, the military, and other U.S. government agencies. NASA's Advanced Space Transportation Program (ASTP) proposes a vision of the future where space travel is as routine as in today's commercial air transportation systems. Dramatically lower launch costs will be required to make this vision a reality. In order to provide more affordable access to space, NASA has established new goals in its Aeronautics and Space Transportation plan. These goals target a reduction in the cost of launching payloads to LEO to $lo00 per pound ($2200 per kilogram) by 2007 and to $100'~ per pound by 2025 while increasing safety by orders of magnitude. Several programs within NASA are addressing innovative propulsion systems that offer potential for reducing launch costs. Various air-breathing propulsion systems currently are being investigated under these programs. The NASA Aerospace Propulsion and Power Base Research and Technology Program supports long-term fundamental research and is managed at GLenn Research Center. Currently funded areas relevant to space transportation include hybrid hyperspeed propulsion (HHP) and pulse detonation engine (PDE) research. The HHP Program currently is addressing rocket-based combined cycle and turbine-based combined cycle systems. The PDE research program has the goal of demonstrating the feasibility of PDE-based hybrid-cycle and combined cycle propulsion systems that meet NASA's aviation and access-to-space goals. The ASTP also is part of the Base Research and Technology Program and is managed at the Marshall Space Flight Center. As technologies developed under the Aerospace Propulsion and Power Base Research and Technology Program mature, they are incorporated into ASTP. One example of this is rocket-based combined cycle systems that are being considered as part of ASTP. The NASA Ultra Efficient Engine Technology (UEET) Program has the goal of developing propulsion system component technology that is relevant to a wide range of vehicle missions. In addition to subsonic and supersonic speed regimes, it includes the hypersonic speed regime. More specifically, component technologies for turbine-based combined cycle engines are being developed as part of UEET.

Whitlow, Woodrow, Jr.↗

NASA NTRS1999

Forced Mixer Nozzle Optimization

Computational fluid dynamic (CFD) and computational acoustic analyses (CAA) were performed for a TFE731-40 compound nozzle, a TFE731-60 mixer nozzle and an Energy Efficient Engine (E(sup 3)) mixer nozzle for comparison with available data. The CFD analyses were performed with a three dimensional, Navier-Stokes solution of the flowfield on an unstructured grid using the RAMPANT program. The CAA analyses were performed with the NASA Glenn MGB program using a structured grid. A successful aerodynamic solution for the TFE731-40 compound nozzle operating statically was obtained, simulating an engine operating on a test stand. Analysis of the CFD results of the TFE731-40 with the MGB program produced predicted sound power levels that agree quite well with the measured data front full-scale static engine tests. Comparison of the predicted sound pressure with the data show good agreement near the jet axis, but the noise levels are overpredicted at angles closer to the inlet. The predicted sound power level for the TFE731-60 did not agree as well with measured static engine data as the TFE731-40. Although a reduction in the predicted noise level due to the mixed flow was observed, the reduction was not as significant as the measured data. The analysis of the V2 mixer from the E(sup 3) study showed that peak temperatures predicted in the mixer exit flowfield were within 5 percent of the values measured by the exit probes. The noise predictions of the V2 mixer nozzle tended to be 3-5 dB higher in peak noise level than the measurements. In addition, the maximum frequency of the noise was also overpredicted. An analysis of the 3 candidate mixer nozzle configurations demonstrated the feasibility of using centerbody lobes and porosity to improve mixing efficiency. A final configuration was designed with a predicted thermal mixing efficiency that was 5 percent higher than the 3 candidate mixers. The results of the MGB noise calculations show that the final design will exceed the design goal of a 3 dB reduction in noise as compared to the baseline TFE731-40.

Sheoran, Yogi↗

NASA NTRS2005

Effects of High-Temperature Exposures on the Fatigue Life of Disk Superalloys Examined

Tests used to characterize the low-cycle-fatigue resistance of disk superalloys are usually performed at cyclic frequencies of 0.33 Hz or faster. However, service conditions for disks in some aerospace and land-based gas turbine engines can produce major cycle periods extending from minutes to hours and days. Over a service life, this can produce total service times near the maximum temperature that exceed 100 hr for aerospace applications and 100,000 hr for land-based applications. Such time-dependent effects of realistic mission cycles on fatigue resistance can be significant in superalloy disks, and need to be considered for accurate disk life prediction. The purpose of this study at the NASA Glenn Research Center was to examine the effects of extended exposures and extended cycle periods on the fatigue resistance of two disk superalloys. Current alloy Udimet 720 (Special Metals Corporation, Huntington, WV) disk material was provided by Solar Turbines/Caterpillar Co., and advanced alloy ME3 was provided by the NASA Ultra-Efficient Engine Technologies (UEET) Project, in powder-metallurgy-processed, supersolvus heat-treated form. Fatigue specimens were fully machined and exposed in air at temperatures of 650 to 704 C for extended times. Then, they were tested using conventional fatigue tests with a total strain range of 0.70 percent and a minimum-to-maximum strain ratio of zero to determine the effects of prior exposure on fatigue resistance. Subsequent tests with extended dwells at minimum strain in each fatigue cycle were performed to determine cyclic exposure effects.

Gabb, Timothy P.↗

NASA NTRS1994

Central coast designs: The Eightball Express. Taking off with convention, cruising with improvements and landing with absolute success

The airline industry is very competitive, resulting in most U.S. and many international airlines being unprofitable. Because of this competition the airlines have been engaging in fare wars (which reduce revenue generated by transporting passengers) while inflation has increased. This situation of course is not developing revenue for the airlines. To revive the airlines to profitability, the difference between revenue received and airline operational cost must be improved. To solve these extreme conditions, the Eightball Express was designed with the main philosophy of developing an aircraft with a low direct operating cost and acquisition cost. Central Coast Designs' (CCD) aircraft utilizes primarily aluminum in the structure to minimize manufacturing cost, supercritical airfoil sections to minimize drag, and fuel efficient engines to minimize fuel burn. Furthermore, the aircraft was designed using Total Quality Management and Integrated Product Development to minimize development and manufacturing costs. Using these primary cost reduction techniques, the Eightball Express was designed to meet the Lockheed/AIAA Request for Proposal (RFP) requirements of a low cost, 153 passenger, 3000 nm. range transport. The Eightball Express is able to takeoff on less than a 7000 ft. runway, cruise at Mach 0.82 at an altitude of 36,000 ft. for a range of 3,000 nm., and lands on a 5,000 ft. runway. lt is able to perform this mission at a direct operating cost of 3.51 cents/available seat mile in 1992 dollars while the acquisition cost is only $28 million in 1992 dollars. By utilizing and improving on proven technologies, CCD has produced an efficient low cost commercial transport for the future.

Davis, Ryan Edwin↗

NASA NTRS2003

Superalloy Disk With Dual-Grain Structure Spin Tested

Advanced nickel-base disk alloys for future gas turbine engines will require greater temperature capability than current alloys, but they must also continue to deliver safe, reliable operation. An advanced, nickel-base disk alloy, designated Alloy 10, was selected for evaluation in NASA s Ultra Safe Propulsion Project. Early studies on small test specimens showed that heat treatments that produced a fine grain microstructure promoted high strength and long fatigue life in the bore of a disk, whereas heat treatments that produced a coarse grain microstructure promoted optimal creep and crack growth resistance in the rim of a disk. On the basis of these results, the optimal combination of performance and safety might be achieved by utilizing a heat-treatment technology that could produce a fine grain bore and coarse grain rim in a nickel-base disk. Alloy 10 disks that were given a dual microstructure heat treatment (DMHT) were obtained from NASA s Ultra-Efficient Engine Technology (UEET) Program for preliminary evaluation. Data on small test specimens machined from a DMHT disk were encouraging. However, the benefit of the dual grain structure on the performance and reliability of the entire disk still needed to be demonstrated. For this reason, a high temperature spin test of a DMHT disk was run at 20 000 rpm and 1500 F at the Balancing Company of Dayton, Ohio, under the direction of NASA Glenn Research Center personnel. The results of that test showed that the DMHT disk exhibited significantly lower crack growth than a disk with a fine grain microstructure. In addition, the results of these tests could be accurately predicted using a two-dimensional, axisymmetric finite element analysis of the DMHT disk. Although the first spin test demonstrated a significant performance advantage associated with the DMHT technology, a second spin test on the DMHT disk was run to determine burst margin. The disk burst in the web at a very high speed, over 39 000 rpm, in line with the predicted location and speed. Furthermore, significant growth of the disk was observed before failure, in line with predictions, clearly demonstrating the reliability and safety of the DMHT technology. Although successful spin testing in Ultra Safe's Nickel Disk Program represents a significant milestone for DMHT technology, realistic engine operation will require repeated loading of a DMHT nickel disk. For this reason, a cyclic spin test study of DMHT nickel disk technology has been proposed to start in fiscal year 2003 under NASA's Aviation Safety Program. The goal of this program will be to determine the fatigue failure mechanism in DMHT nickel disks, thereby demonstrating the reliability and safety of DMHT technology under repetitive loading conditions encountered in realistic engine operation.

Gayda, John↗

NASA NTRS2008

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗