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The purpose of this paper is to give an outline of the present state of development and point out the possibilities available for the further increase in the power/displacement ratio, the economy, and the reliability of the engine. Some of the aspects discussed are methods of increasing take-off power, the various methods of preparation of the fuel mixture and their effect on power, economy, and safety.
Report presents requirements of internal combustion engines suitable for aircraft. Topics include: (1) service requirements for aeronautic engines - power versus weight, reliability, and adaptability factors, (2) general characteristics of present aero engines, (3) aero engine processes and functions of parts versus power-weight ratio, reliability, and adaptability factors, and (4) general arrangement, form, proportions, and materials of aero parts - power-weight ratio, reliability, and adaptability.
The concept for the DEEC had its origin in the early 1970s. At that time it was recognized that the F100 engine performance, operability, reliability, and cost could be substantially improved by replacing the original mechanical/supervisory electronic control system with a full-authority digital control system. By 1978, the engine manufacturer had designed and initiated the procurement of flight-qualified control system hardware. As a precursor to an integrated controls program, a flight evaluation of the DEEC system on the F-15 aircraft was proposed. Questions regarding the management of the DEEC flight evaluation program are discussed along with the program elements, the technical results of the F-15 evaluation, and the impact of the flight evaluation on after-burning turbofan controls technology and its use in and application to military aircraft. The lessons learned through the conduct of the program are discussed.
The higher performance levels of modern gas turbine engines present significant challenges in the reliability of materials in the turbine. The increased engine temperatures required to achieve the higher performance levels reduce the strength of the materials used in the turbine sections of the engine. Various forms of Thermal Barrier Coatings (TBC's) have been used for many years to increase the reliability of gas turbine engine components. Recent experience with the Physical Vapor Deposition (PVD) process using ceramic material has demonstrated success in extending the service life of turbine blades and nozzles. Engine test results of turbine components with a 125 micrometer (0.005 in) PVD TBC have demonstrated component operating temperatures of 56-83 C (100-150 F) lower than uncoated components. Engine testing has also revealed the TBC is susceptible to high angle particle impact damage. Sand particles and other engine debris impact the TBC surface at the leading edge of airfoils and fracture the PVD columns. As the impacting continues the TBC erodes away in local areas. Analysis of the eroded areas has shown a slight increase in temperature over a fully coated area, however, a significant temperature reduction was realized over an airfoil without any TBC.
The higher performance levels of modern gas turbine engines present significant challenges in the reliability of materials in the turbine. The increased engine temperatures required to achieve the higher performance levels reduce the strength of the materials used in the turbine sections of the engine. Various forms of thermal barrier coatings (TBC's) have been used for many years to increase the reliability of gas turbine engine components. Recent experience with the physical vapor deposition (PVD) process using ceramic material has demonstrated success in extending the service life of turbine blades and nozzles. Engine test results of turbine components with a 125 micron (0.005 in) PVD TBC have demonstrated component operating temperatures of 56-83 C (100-150 F) lower than non-PVD TBC components. Engine testing has also revealed the TBC is susceptible to high angle particle impact damage. Sand particles and other engine debris impact the TBC surface at the leading edge of airfoils and fracture the PVD columns. As the impacting continues, the TBC erodes away in local areas. Analysis of the eroded areas has shown a slight increase in temperature over a fully coated area, however a significant temperature reduction was realized over an airfoil without TBC.
A self-learning, sensor fail-operational, control system for the TF30-P-3 afterburning turbofan engine was designed and evaluated. The sensor fail-operational control system includes a digital computer program designed to operate in conjunction with the standard TF30-P-3 bill-of-materials control. Four engine measurements and two compressor face measurements are tested. If any engine measurements are found to have failed, they are replaced by values synthesized from computer-stored information. The control system was evaluated by using a realtime, nonlinear, hybrid computer engine simulation at sea level static condition, at a typical cruise condition, and at several extreme flight conditions. Results indicate that the addition of such a system can improve the reliability of an engine digital control system.
The Gas Turbine Transit Bus Demonstration Program was designed to demonstrate and evaluate the operation of gas turbine engines in transit coaches in revenue service compared with diesel powered coaches. The main objective of the program was to accelerate development and commercialization of automotive gas turbines. The benefits from the installation of this engine in a transit coach were expected to be reduced weight, cleaner exhaust emissions, lower noise levels, reduced engine vibration and maintenance requirements, improved reliability and vehicle performance, greater engine braking capability, and superior cold weather starting. Four RTS-II advanced design transit coaches were converted to gas turbine power using engines and transmissions. Development, acceptance, performance and systems tests were performed on the coaches prior to the revenue service demonstration.
Jet engines, although highly reliable and safe, do experience malfunctions that cause flight delays, passenger stress, and in some cases, in conjunction with inappropriate crew response, contribute to airplane accidents. On rare occasions, the anomalous engine behavior is not recognized until it is too late for the pilots to do anything to prevent or mitigate the resulting engine malfunction causing in-flight shutdowns (IFSDs), aborted takeoffs (ATOs), or loss of thrust control (LOTC). In some cases, the crew response to a myriad of external stimuli and existing training procedures is the source of the problem mentioned above. The problem is the reduction of jet engine malfunctions (IFSDs, ATOs, and LOTC) and inappropriate crew response (PSM+ICR) through the use of evolving and advanced technologies. The solution is to develop the overall system health maintenance architecture, detection and accommodation technologies, processes, and enhanced crew interfaces that would enable a significant reduction in IFSDs, ATOs, and LOTC. This program defines requirements and proposes a preliminary design concept of an architecture that enables the realization of the solution.
Aircraft engines have evolved into a highly complex system to meet ever-increasing demands. The evolution of engine technologies has primarily been driven by fuel efficiency, reliability, as well as engine noise concerns. One of the sources of engine noise is pressure fluctuations that are induced on the stator vanes. These local pressure fluctuations, once produced, propagate and coalesce with the pressure waves originating elsewhere on the stator to form a spinning pressure pattern. Depending on the duct geometry, air flow, and frequency of fluctuations, these spinning pressure patterns are self-sustaining and result in noise which eventually radiate to the far-field from engine. To investigate the nature of vane pressure fluctuations and the resulting engine noise, unsteady pressure signatures from an array of embedded acoustic sensors are recorded as a part of vane noise source diagnostics. Output time signatures from these sensors are routed to a control and data processing station adding complexity to the system and cable loss to the measured signal. "Smart" wireless sensors have data processing capability at the sensor locations which further increases the potential of wireless sensors. Smart sensors can process measured data locally and transmit only the important information through wireless communication. The aim of this wireless noise telemetry task was to demonstrate a single acoustic sensor wireless link for unsteady pressure measurement, and thus, establish the feasibility of distributed smart sensors scheme for aircraft engine vane surface unsteady pressure data transmission and characterization.
The conversion of carbon dioxide into higher value products is a key challenge for the development of closed-loop life support systems for human space flight. Much of the past research on bioregenerative life support systems has focused on plant growth chambers as a solution for CO2 removal and O2 generation, but photosynthetic microorganisms may also have a role to play in these functions. Cyanobacteria have the advantages of relatively high CO2 fixation rates and fairly well-developed molecular biology tools, allowing for genetic engineering approaches to strain improvement. Manned missions to Mars or other targets beyond low Earth orbit will require advances in the nutritional systems for life support on these longer duration missions. A key challenge will likely be supplementing pre-packaged meals with specific nutrients that will be deficient due to problems in long-term storage or low abundance. Vitamin K is one such nutrient that may be important as a supplement. Production of vitamin K for nutrient supplementation during spaceflight will likely require genetic engineering of microorganisms to increase vitamin titers. A microbial bioreactor system that could efficiently convert CO2 to nutritional supplements would be a valuable component for a future advanced life support system. We are exploring biological systems to determine the feasibility of using bioreactors to convert CO2 to higher-value products. We are examining the performance of photosynthetic bacteria engineered to produce sugars, determining rates of production and reliability. We are also engineering microbes to produce higher titers of vitamin K and other potentially important nutrients. The results of this research will offer demonstrations of potential technologies that could be developed further in the future. This work will also provide valuable information for understanding basic science questions about the use of genetically engineered microbes in the microgravity environment.
The Johnson Space Center (JSC) Safety & Mission Assurance (S&MA) Directorate s Risk and Reliability Analysis Group provides both mathematical and engineering analysis expertise in the areas of Probabilistic Risk Assessment (PRA), Reliability and Maintainability (R&M) analysis, and data collection and analysis. The fundamental goal of this group is to provide National Aeronautics and Space Administration (NASA) decisionmakers with the necessary information to make informed decisions when evaluating personnel, flight hardware, and public safety concerns associated with current operating systems as well as with any future systems. The Analysis Group includes a staff of statistical and reliability experts with valuable backgrounds in the statistical, reliability, and engineering fields. This group includes JSC S&MA Analysis Branch personnel as well as S&MA support services contractors, such as Science Applications International Corporation (SAIC) and SoHaR. The Analysis Group s experience base includes nuclear power (both commercial and navy), manufacturing, Department of Defense, chemical, and shipping industries, as well as significant aerospace experience specifically in the Shuttle, International Space Station (ISS), and Constellation Programs. The Analysis Group partners with project and program offices, other NASA centers, NASA contractors, and universities to provide additional resources or information to the group when performing various analysis tasks. The JSC S&MA Analysis Group is recognized as a leader in risk and reliability analysis within the NASA community. Therefore, the Analysis Group is in high demand to help the Space Shuttle Program (SSP) continue to fly safely, assist in designing the next generation spacecraft for the Constellation Program (CxP), and promote advanced analytical techniques. The Analysis Section s tasks include teaching classes and instituting personnel qualification processes to enhance the professional abilities of our analysts as well as performing major probabilistic assessments used to support flight rationale and help establish program requirements. During 2008, the Analysis Group performed more than 70 assessments. Although all these assessments were important, some were instrumental in the decisionmaking processes for the Shuttle and Constellation Programs. Two of the more significant tasks were the Space Transportation System (STS)-122 Low Level Cutoff PRA for the SSP and the Orion Pad Abort One (PA-1) PRA for the CxP. These two activities, along with the numerous other tasks the Analysis Group performed in 2008, are summarized in this report. This report also highlights several ongoing and upcoming efforts to provide crucial statistical and probabilistic assessments, such as the Extravehicular Activity (EVA) PRA for the Hubble Space Telescope service mission and the first fully integrated PRAs for the CxP's Lunar Sortie and ISS missions.
Johnson Space Center (JSC) provides research, engineering, development, integration, and testing of hardware and software technologies for exercise systems applications in support of human spaceflight. This includes sustaining the current suite of on-orbit exercise devices by reducing maintenance, addressing obsolescence, and increasing reliability through creative engineering solutions. Advanced exercise systems technology development efforts focus on the sustainment of crew's physical condition beyond Low Earth Orbit for extended mission durations with significantly reduced mass, volume, and power consumption when compared to the ISS.
Johnson Space Center (JSC) provides research, engineering, development, integration, and testing of hardware and software technologies for exercise systems applications in support of human spaceflight. This includes sustaining the current suite of on-orbit exercise devices by reducing maintenance, addressing obsolescence, and increasing reliability through creative engineering solutions. Advanced exercise systems technology development efforts focus on the sustainment of crew's physical condition beyond Low Earth Orbit for extended mission durations with significantly reduced mass, volume, and power consumption when compared to the ISS.
A workstation is being developed that provides a computational environment for all NASA engineers across application boundaries, which automates reuse of existing NASA software and designs, and efficiently and effectively allows new programs and/or designs to be developed, catalogued, and reused. The generic workstation is made domain specific by specialization of the user interface, capturing engineering design expertise for the domain, and by constructing/using a library of pertinent information. The incorporation of software reusability principles and expert system technology into this workstation provide the obvious benefits of increased productivity, improved software use and design reliability, and enhanced engineering quality by bringing engineering to higher levels of abstraction based on a well tested and classified library.
The paper provides an engineering analysis approach for assessing reliability of NDE flaw detection using smaller number of demonstration data points. It explores dependence of probability of detection (POD), probability of false positive (POF), on contrast-to-noise ratio, and net decision threshold-to-noise ratio in a simulated data; and draws some generically applicable inferences to devise the approach. ASTM nondestructive evaluation standards provide requirements on signal-to-noise ratio and/or contrast-to-noise ratio in order to provide reliable flaw detection and limit false positive calls. POD analysis of inspection test data results in an estimated flaw size, denoted by 𝑎90/95. This flaw size has 90% POD and minimum 95% confidence. POF is also estimated in the analysis. POD demonstration requires specimens with flaws of known size. In many situations, it is very expensive to produce the large number of flaws required for the POD analysis. In some situations, only real flaws can truly represent the flaws for demonstration. Real flaws of correct size and location in part configuration specimen may be difficult to produce, if not impossible. Here, an engineering analysis approach is devised using simulation to assess reliability of NDE technique when a limited number of flaws are available for demonstration. In this simulation, a technique is considered reliable, if it provides flaw detectability size equal to or better than the theoretical 𝑎90𝑡ℎ used in simulation and also provides a POF less than or equal to a chosen value. The paper uses simulated signal response versus flaw size data to devise the approach. Linear correlation is used between the signal response data and flaw size. POD software mh1823 uses generalized linear model (GLM) in POD analysis after transforming the flaw size and signal response, if needed, using logarithm. Therefore, this approach is in agreement with the linear signal correlation used in mh1823. Using the POD analysis of data, generic conditions on contrast-to-noise ratio and net decision threshold-to-noise ratio are derived for reliable flaw detection. In order to assess technique reliability using the engineering approach, signal response-to-flaw size correlation about the flaw size of concern is needed. In addition, measurement of noise is also needed. If the technique meets the above requirements, assumption of linear signal-to-flaw size correlation and conditions on noise, then the technique can be assessed using this analysis as it fits the underlying POD model used here. The approach is conservative and is designed to provide a larger flaw size compared to the POD approach. Such NDE technique assessment approach, although, not as rigorous as POD, can be cost effective if the larger flaw size can be tolerated. Typically, this is a situation for all quality control NDE inspections. Here, an NDE technique needs to be reliable and 𝑎90/95 is not estimated, but the assessed flaw size is assumed to be larger than the unknown a90 due to conservative factors or margins. Applicability of the approach for assessing reliability of flaw detection in x-ray radiography and 2D imaging in general is also explored.
Assessment of environmental engineering and testing methods used in development of various spacecraft systems
Presentation for RISA stakeholder meeting
Ceramic thermal and environmental barrier coatings (TEBCs) are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments, and extend component lifetimes. For future high performance engines, the development of advanced ceramic barrier coating systems will allow these coatings to be used to simultaneously increase engine operating temperature and reduce cooling requirements, thereby leading to significant improvements in engine power density and efficiency. In order to meet future engine performance and reliability requirements, the coating systems must be designed with increased high temperature stability, lower thermal conductivity, and improved thermal stress and erosion resistance. In this paper, ceramic coating design and testing considerations will be described for high temperature and high-heat-flux engine applications in hot corrosion and oxidation, erosion, and combustion water vapor environments. Further coating performance and life improvements will be expected by utilizing advanced coating architecture design, composition optimization, and improved processing techniques, in conjunction with modeling and design tools.