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The status of research efforts to apply low to intermediate temperature composite materials and advanced high temperature materials to engine components is reviewed. Emerging materials technologies and their potential benefits to aircraft gas turbines were emphasized. The problems were identified, and the general state of the technology for near term use was assessed.
Aircraft safety is reviewed by first establishing a perspective of air transportation accidents as a function of calendar year, geographic area, and phase of flight, and then by describing the threats to safety and NASA research underway in the three representative areas of engine operational problems, meteorological phenomena, and fire. Engine rotor burst protection, aircraft nacelle fire extinguishment, the aircraft-weather interface, severe weather wind shears and turbulence, clear air turbulence, and lightning are among the topics covered. Fire impact management through fire resistant materials technology development is emphasized.
The principal thrust of the LSST program is to develop the materials technology required for confident design of large space systems such as antennas and platforms. Areas of research in the FY-79 program include evaluation of polysulfones, measurement of the coefficient of thermal expansion of low expansion composite laminates, thermal cycling effects, and cable technology. The development of new long thermal control coatings and adhesives for use in space is discussed. The determination of radiation damage mechanisms of resin matrix composites and the formulation of new polymer matrices that are inherently more stable in the space environment are examined.
Advances in airframe structure and materials technology for supersonic cruise aircraft are reported with emphasis on titanium and composite structures. The operation of the Concorde is examined as a baseline for projections into the future. A market survey of U.S. passenger attitudes and preferences, the impact of advanced air transport technology and the integration of systems for the advanced SST and for a smaller research/business jet vehicle are also discussed.
The development of a high temperature solar thermal receiver is described. A prototype receiver and associated test support (auxiliary) hardware was fabricated. Shakedown and initial performance tests of the prototype receiver were performed. Maximum outlet temperatures of 1600 F were achieved at 100% solar (70-75 kW) input power with 900 F inlet temperatures and a subsequent testing was concluded by a 2550 F outlet run. The window retaining assembly was modified to improve its tolerance for thermal distortion of the flanges. It is shown that cost effective receiver designs can be implemented within the framework of present materials technology.
The primary objective of the Conservation of Strategic Aerospace Materials (COSAM) Program is to help reduce the dependence of the United States aerospace industry on strategic metals by providing the materials technology needed to minimize the strategic metal content of critical aerospace components with prime emphasis on components for gas turbine engines. Initial emphasis was placed in the area of strategic element substinction. Specifically, the role of cobalt in nickel base and cobalt base superalloys vital to the aerospace industry is being examined in great detail by means of cooperative university-industry-government research efforts. Investigations are underway in the area of "new classes" of alloys. Specifically, a study was undertaken to investigate the mechanical and physical properties of intermetallics that contain a minimum of the strategic metals. Current plans for the much larger COSAM Program are also presented.
The background and history of the Stirling engine, the technology, materials, components, controls, and systems, and a technical assessment of automotive stirling engines are presented.
Advances in continuum modeling, progress in reduction methods, and analysis and modeling needs for large space structures are covered with specific attention given to repetitive lattice trusses. As far as continuum modeling is concerned, an effective and verified analysis capability exists for linear thermoelastic stress, birfurcation buckling, and free vibration problems of repetitive lattices. However, application of continuum modeling to nonlinear analysis needs more development. Reduction methods are very effective for bifurcation buckling and static (steady-state) nonlinear analysis. However, more work is needed to realize their full potential for nonlinear dynamic and time-dependent problems. As far as analysis and modeling needs are concerned, three areas are identified: loads determination, modeling and nonclassical behavior characteristics, and computational algorithms. The impact of new advances in computer hardware, software, integrated analysis, CAD/CAM stems, and materials technology is also discussed.
The advancement of the state-of-the-art in aircraft bearing materials technology is reviewed. Current specifications and design practices resulting from NASA-sponsored programs are included.
Because of financial and political constraints, strategic aerospace materials required for the hot section of future engines might be in short supply. As an alternative to these strategic materials, this study examines the use of a cooling air heat exchanger in combination with less advanced hot section materials. Cycle calculations are presented for future turbofan systems with overall pressure ratios to 65, bypass ratios near 13, and combustor exit temperatures to 3260 R. These calculations quantify the effect on TSFC of using a decreased materials technology in a turbofan system. The calculations show that the cooling air heat exchanger enables the feasibility of these engines.
Because of financial and political constraints, strategic aerospace materials required for the hot section of future engines might be in short supply. As an alternative to these strategic materials, this study examines the use of a cooling air heat exchanger in combination with less advanced hot section materials. Cycle calculations are presented for future turbofan systems with overall pressure ratios to 65, bypass ratios near 13, and combustor exit temperatures to 3260 R. These calculations quantify the effect on TSFC of using a decreased materials technology in a turbofan system. The calculations show that the cooling air heat exchanger enables the feasibility of these engines. Previously announced in STAR as N83-34946
These are the proceedings of the High Temperature Polymer Matrix Composites Conference held at the NASA Lewis Research Center on March 16 to 18, 1983. The purpose of the conference is to provide scientists and engineers working in the field of high temperature polymer matrix composites an opportunity to review, exchange, and assess the latest developments in this rapidly expanding area of materials technology. Technical papers are presented in the following areas: (1) matrix development; (2) adhesive development; (3) characterization; (4) environmental effects; and (5) applications.
The Advanced Systems Research Group supports the photovoltaic advanced R&D (PV AR&D) project by providing outdoor (global) testing of PV cells, submodules, modules, and arrays. The group also provides in house engineering and analysis to identify and determine how technical issues such as cell/module/system adaptations, long term stability, reliability, economics, materials availability, safety, and environmental impacts affect the development and ultimate use of advanced PV thin film, innovative cell, and material technologies. A major thrust of the research effort is to develop and utilize instrumentation and procedures for monitoring and analyzing PV cells and submodules including outdoor performance and stability testing and life cycle accelerated stress testing. To accomplish the above, the solar energy research institute (SERI) outdoor PV test facility was established in 1982. The group has designed testing systems and analysis procedures for, and has tested, numerous amorphous silicon thin film submodules provided by SERI subcontractors and has performed long term outdoor stability tests on CdS/CuIr Se sub 2 and hydrogen passivated silicon solar cells. A significant contribution from this facility over the past year was the testing of large area amorphous silicon submodules.
Single junction GaAs solar cells have already attained an efficiency of 19% AMO which could potentially be increased to approx 20%, with some optimization. To achieve the higher efficiency the concept of multibandgap solar cells which utilizes a wider region of the solar spectrum should be sed. One of the materials for fabricating the top cell in a multibandgap solar cell is AlGaAs because it is compatible with GaAs in bandgap and lattice match. This is a very important consideration from the materials technology point of view, and the viability of this approach is evaluated.
Composite material technology was applied to the solid rocket booster by the development of a carbon filament-epoxy resin case which yields a net increase of 4000 lbs. in payload in the shuttle. The question of reusability of the new composite tanks has not yet been answered and will depend on the toughness of the matrix resin. The present study was aimed at providing conditions whereby test specimens of the epoxy resin (EPON/85) and curing agents of systematically varied structures could be produced in a controlled manner. Three sets of conditions were found that might allow the isolation of the structural effects on toughness from the cure effects. The kinetic methods leading to the determination of these conditions are described.
In the present quantitative consideration of space processing concepts for chemicals, theoretical parametric calculations are supplemented by a bench scale experiment. Attention is given to the case of water splitting to generate hydrogen and oxygen for a simple rocket motor that can be used in periodic thrusting. This concept of in situ propellant production is treated in detail and compared with more recent energy and materials technologies.
Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology that has both performance and durability benefits. In order to achieve these benefits, however, the TBC system must be reliable. Prediction of the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry is examined. The plasma sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor depositon (EB-PVD) process by Temescal.
The development of directionally solidified and single crystal alloys is perhaps the most important recent advancement in hot section materials technology. The objective is to develop knowledge that enables the designer to improve anisotropic gas turbine parts to their full potential. Two single crystal alloys selected were PWA 1480 and Alloy 185. The coatings selected were an overlay coating, PWA 286, and an aluminide diffusion coating, PWA 273. The constitutive specimens were solid and cylindrical; the fatigue specimens were hollow and cylindrical. Two thicknesses of substrate are utilized. Specimens of both thickness (0.4 and 1.5 mm) will be coated and then tested for tensile, creep, and fatigue properties.