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NASA NTRS1997

An Experimental Study of the Effect of Wake Passing on Turbine Blade Film Cooling

The effect of wake passing on the showerhead film cooling performance of a turbine blade has been investigated experimentally. The experiments were performed in an annular turbine cascade with an upstream rotating row of cylindrical rods. Nickel thin-film gauges were used to determine local film effectiveness and Nusselt number values for various injectants, blowing ratios, and Strouhal numbers. Results indicated a reduction in film effectiveness with increasing Strouhal number, as well as the expected increase in film effectiveness with blowing ratio. An equation was developed to correlate the span-average film effectiveness data. The primary effect of wake unsteadiness was found to be correlated by a streamwise-constant decrement of 0.094.St. Steady computations were found to be in excellent agreement with experimental Nusselt numbers, but to overpredict experimental film effectiveness values. This is likely due to the inability to match actual hole exit velocity profiles and the absence of a credible turbulence model for film cooling.

Heidmann, James D.↗

NASA NTRS1999

Friction stir welding process to repair voids in aluminum alloys

The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

Rosen, Charles D.↗

NASA NTRS2011

2014/2219 Tri-Point Crack Analysis

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. The objective of this study was to evaluate the deformation response at the tips of cracks located in the heat affected zone of friction plug welds and to study the fracture behavior of welds with defects in the form of fatigue cracks. The study used existing 2014-T6 to 2219-T87 self-reacting friction stir weld panels with 2219-T87 friction plug welds. Electro-discharge machined (EDM) notches were machined into the heat affected zone of the plug at the plug-to-base metal interface. Samples were then cycled to generate a fatigue crack emanating from the notch. After the fatigue crack reached a pre-defined length, a speckle pattern was applied and the ARAMIS system (a three dimensional imaging correlation system) was used to measure the deformations at the crack tip under a sequence of loads. Testing was conducted at ambient laboratory conditions. Fracture data from the testing was analyzed to evaluate residual strength capability of the panel as a function of flaw size. ARAMIS strain data was evaluated to examine strain and deformation patterns that develop around the crack tip and at the plug/weld interfaces. Four samples were used in this study, with three samples in a post-weld heat treated condition. Three samples contained large diameter plugs (M5) and one sample contained a small diameter plug (M3). Two samples were 4 inches in width and two samples were 8.5 inches in width. All samples failed through the precrack with residual strengths ranging from 37 ksi to 42 ksi.

Horton, Karla Renee↗

NASA NTRS2011

Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

Horton, Karla Renee↗

NASA NTRS2012

Damage Tolerance Assessment of Friction Pull Plug Welds in an Aluminum Alloy

Friction stir welding is a solid state welding process used in the fabrication of cryogenic propellant tanks. Self-reacting friction stir welding is one variation of the friction stir weld process being developed for manufacturing tanks. Friction pull plug welding is used to seal the exit hole that remains in a circumferential self-reacting friction stir weld. A friction plug weld placed in a self-reacting friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data relating residual strength capability to flaw size in an aluminum alloy friction plug weld will be presented.

McGill, Preston↗

NASA NTRS2015

Investigation of Spiral and Sweeping Holes

Surface infrared thermography, hotwire anemometry, and thermocouple surveys were performed on two new film cooling hole geometries: spiral/rifled holes and fluidic sweeping holes. The spiral holes attempt to induce large-scale vorticity to the film cooling jet as it exits the hole to prevent the formation of the kidney shaped vortices commonly associated with film cooling jets. The fluidic sweeping hole uses a passive in-hole geometry to induce jet sweeping at frequencies that scale with blowing ratios. The spiral hole performance is compared to that of round holes with and without compound angles. The fluidic hole is of the diffusion class of holes and is therefore compared to a 777 hole and Square holes. A patent-pending spiral hole design showed the highest potential of the non-diffusion type hole configurations. Velocity contours and flow temperature were acquired at discreet cross-sections of the downstream flow field. The passive fluidic sweeping hole shows the most uniform cooling distribution but suffers from low span-averaged effectiveness levels due to enhanced mixing. The data was taken at a Reynolds number of 11,000 based on hole diameter and freestream velocity. Infrared thermography was taken for blowing rations of 1.0, 1.5, 2.0, and 2.5 at a density ration of 1.05. The flow inside the fluidic sweeping hole was studied using 3D unsteady RANS.

infrared thermography↗

NASA NTRS2018

Toward Cooling Uniformity: Investigation of Spiral, Sweeping Holes, and Unconventional Cooling Paradigms

Surface infrared thermography, hotwire anemometry, and thermocouple surveys were performed on two new film cooling hole geometries: spiral/rifled holes and fluidic sweeping holes. Ways to quantify the efficacy of novel cooling holes that are asymmetric, not uniformly spaced or that show variation from hole to hole are presented. The spiral holes attempt to induce large-scale vorticity to the film cooling jet as it exits the hole to prevent the formation of the kidney shaped vortices commonly associated with film cooling jets. The fluidic sweeping hole uses a passive in-hole geometry to induce jet sweeping at frequencies that scale with blowing ratios. The spiral hole performance is compared to that of round holes with and without compound angles. The fluidic hole is of the diffusion class of holes and is therefore compared to a 777 hole and square holes. A patent-pending spiral hole design showed the highest potential of the nondiffusion type hole configurations. Velocity contours and flow temperature were acquired at discreet cross-sections of the downstream flow field. The passive fluidic sweeping hole shows the most uniform cooling distribution but suffers from low span-averaged effectiveness levels due to enhanced mixing. The data was taken at a Reynolds number of 11,000 based on hole diameter and freestream velocity. Infrared thermography was taken for blowing ratios of 1.0, 1.5, 2.0, and 2.5 at a density ratio of 1.05. The flow inside the fluidic sweeping hole was studied using 3D unsteady RANS. A section on ideas for future work is included that addresses issues of quantifying cooling uniformity and provides some ideas for changing the way we think about cooling such as changing the direction of cooling or coupling acoustic devices to cooling holes to regulate frequency.

Shyam, Vikram↗

NASA NTRS2000

Effect of Film-Hole Shape on Turbine Blade Film Cooling Performance

The detailed heat transfer coefficient and film cooling effectiveness distributions as well as tile detailed coolant jet temperature profiles on the suction side of a gas turbine blade A,ere measured using a transient liquid crystal image method and a traversing cold wire and a traversing thermocouple probe, respectively. The blade has only one row of film holes near the gill hole portion on the suction side of the blade. The hole geometries studied include standard cylindrical holes and holes with diffuser shaped exit portion (i.e. fanshaped holes and laidback fanshaped holes). Tests were performed on a five-blade linear cascade in a low-speed wind tunnel. The mainstream Reynolds number based on cascade exit velocity was 5.3 x 10(exp 5). Upstream unsteady wakes were simulated using a spoke-wheel type wake generator. The wake Strouhal number was kept at 0 or 0.1. Coolant blowing ratio was varied from 0.4 to 1.2. Results show that both expanded holes have significantly improved thermal protection over the surface downstream of the ejection location, particularly at high blowing ratios. However, the expanded hole injections induce earlier boundary layer transition to turbulence and enhance heat transfer coefficients at the latter part of the blade suction surface. In general, the unsteady wake tends to reduce film cooling effectiveness.

Han, J. C.↗

NASA NTRS1930

Investigation of air flow in open-throat wind tunnels

Tests were conducted on the 6-inch wind tunnel of the National Advisory Committee for Aeronautics to form a part of a research on open-throat wind tunnels. The primary object of this part of the research was to study a type of air pulsation which has been encountered in open-throat tunnels, and to find the most satisfactory means of eliminating such pulsations. In order to do this it was necessary to study the effects of different variable on all of the important characteristics of the tunnel. This paper gives not only the results of the study of air pulsations and methods of eliminating them, but also the effects of changing the exit-cone diameter and flare and the effects of air leakage from the return passage. It was found that the air pulsations in the 6-inch wind tunnel could be practically eliminated by using a moderately large flare on the exit cone in conjunction with leakage introduced by cutting holes in the exit cone somewhat aft of its minimum diameter.

Jacobs, Eastman N↗

NASA NTRS2019

The Effect of Hole Quality on the Bearing Strength of Carbon Fiber Laminates

On programs involving flight hardware for launch vehicles that the author has been involved in over the years, the question always arises as to how to best machine and inspect holes drilled for fasteners. While common sense dictates that ‘well-drilled’ holes are desired over ‘poorly drilled’ holes for bolt bearing applications, the effect of hole quality on the bearing strength of carbon fiber laminates has not been extensively studied in the open literature. If this effect is not quantitatively known, the question of what hole quality needs to be required for the flight hardware cannot be answered. In addition, the function of the part with respect to the holes needs to be taken into account. There is no such thing as a defect-free hole since some chip-out of fibers within the hole will occur regardless of drill bit and backing plate pressure. For most holes machined in a carbon fiber laminate, some extent of delamination and fiber breakout on the entrance and exit of the hole is going to occur. Much time and money can be spent on trying to perfect the drilling technique and subsequent inspection of holes in carbon fiber laminates, including adding extra plies of cloth to the surfaces to help prevent fiber breakout; but is this effort really justified if little-to-no increase in bearing strength is realized by good-quality holes over those of lesser quality?

Nettles, A. T.↗

NASA NTRS1984

Surface and allied studies in silicon solar cells

Measuring small-signal admittance versus frequency and forward bias voltage together with a new transient measurement apparently provides the most reliable and flexible method available for determining back surface recombination velocity and low-injection lifetime of the quasineutral base region of silicon solar cells. The new transient measurement reported here is called short-circuit-current decay (SCCD). In this method, forward voltage equal to about the open-circuit or the maximum power voltage establishes excess holes and electrons in the junction transition region and in the quasineutral regions. The sudden application of a short circuit causes an exiting of the excess holes and electrons in the transition region within about ten picoseconds. From observing the slope and intercept of the subsequent current decay, the base lifetime and surface recombination velocity can be determined. The admittance measurement previously mentioned then enters to increase accuracy particularly for devices for which the diffusion length exceeds the base thickness.

Lindholm, F. A.↗

NASA NTRS1980

The random walk of a drilling laser beam

The disregistry of holes drilled with a pulse laser beam in 330-micron-thick single-crystal silicon-on-sapphire wafers is examined. The exit positions of the holes were displaced from the hole entrance positions on the opposing face of the wafer, and this random displacement increased with the number of laser pulses required. A model in which the bottom of the drill hole experiences small random displacements during each laser pulse is used to describe the experimental observations. It is shown that the average random displacement caused by each pulse is only a few percent of the hole diameter and can be reduced by using as few laser pulses as necessary while avoiding the cracking and spalling of the wafer that occur with a hole drilled with a single pulse.

Anthony, T. R.↗

NASA NTRS2000

Effects of Hole Length, Supply Plenum Geometry, and Freestream Turbulence on Film Cooling Performance

Experimental measurements are presented in this report to document the sensitivity of film cooling performance to the hole length and coolant delivery plenum geometry. Measurements with hot-wire anemometry detail velocity, local turbulence, and spectral distributions over the exit plane of film cooling holes and downstream of injection in the coolant-freestream interaction zone. Measurements of discharge coefficients and adiabatic effectiveness are also provided. Coolant is supplied to the film cooling holes by means of a large, open plenum and through plenums which force the coolant to approach the holes either co-current or counter-current to the freestream. A single row of film cooling holes with 35 degree-inclined streamwise at two coolant-to-freestream velocity ratios, 0.5 and 1.0, is investigated. The coolant-to-freestream density ratio is maintained in the range 0.96 to 1.0. Measurements were taken under high-freestream (FSTI = 12%) and low-freestream turbulence intensity (FSTI = 0.5%) conditions. The results document the effects of the hole L/D, coolant supply plenum geometry, velocity ratio, and FSTI. In general, hole L/D and the supply plenum geometry play influential roles in the film cooling performance. Hole L/D effects, however, are more pronounced. Film cooling performance is also dependent upon the velocity ratio and FSTI.

Burd, Steven W.↗

NASA NTRS2016

Wavefront-Error Performance Characterization for the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM) Science Instruments

The science instruments (SIs) comprising the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM) were tested in three cryogenic-vacuum test campaigns in the NASA Goddard Space Flight Center (GSFC)'s Space Environment Simulator (SES). In this paper, we describe the results of optical wavefront-error performance characterization of the SIs. The wavefront error is determined using image-based wavefront sensing (also known as phase retrieval), and the primary data used by this process are focus sweeps, a series of images recorded by the instrument under test in its as-used configuration, in which the focal plane is systematically changed from one image to the next. High-precision determination of the wavefront error also requires several sources of secondary data, including 1) spectrum, apodization, and wavefront-error characterization of the optical ground-support equipment (OGSE) illumination module, called the OTE Simulator (OSIM), 2) plate scale measurements made using a Pseudo-Nonredundant Mask (PNRM), and 3) pupil geometry predictions as a function of SI and field point, which are complicated because of a tricontagon-shaped outer perimeter and small holes that appear in the exit pupil due to the way that different light sources are injected into the optical path by the OGSE. One set of wavefront-error tests, for the coronagraphic channel of the Near-Infrared Camera (NIRCam) Longwave instruments, was performed using data from transverse translation diversity sweeps instead of focus sweeps, in which a sub-aperture is translated andor rotated across the exit pupil of the system.Several optical-performance requirements that were verified during this ISIM-level testing are levied on the uncertainties of various wavefront-error-related quantities rather than on the wavefront errors themselves. This paper also describes the methodology, based on Monte Carlo simulations of the wavefront-sensing analysis of focus-sweep data, used to establish the uncertainties of the wavefront error maps.

wavefront error↗

NASA NTRS2016

Wavefront-Error Performance Characterization for the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM) Science Instruments

The science instruments (SIs) comprising the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM) were tested in three cryogenic-vacuum test campaigns in the NASA Goddard Space Flight Center (GSFC)'s Space Environment Simulator (SES) test chamber. In this paper, we describe the results of optical wavefront-error performance characterization of the SIs. The wavefront error is determined using image-based wavefront sensing, and the primary data used by this process are focus sweeps, a series of images recorded by the instrument under test in its as-used configuration, in which the focal plane is systematically changed from one image to the next. High-precision determination of the wavefront error also requires several sources of secondary data, including 1) spectrum, apodization, and wavefront-error characterization of the optical ground-support equipment (OGSE) illumination module, called the OTE Simulator (OSIM), 2) F-number and pupil-distortion measurements made using a pseudo-nonredundant mask (PNRM), and 3) pupil geometry predictions as a function of SI and field point, which are complicated because of a tricontagon-shaped outer perimeter and small holes that appear in the exit pupil due to the way that different light sources are injected into the optical path by the OGSE. One set of wavefront-error tests, for the coronagraphic channel of the Near-Infrared Camera (NIRCam) Longwave instruments, was performed using data from transverse translation diversity sweeps instead of focus sweeps, in which a sub-aperture is translated and/or rotated across the exit pupil of the system. Several optical-performance requirements that were verified during this ISIM-level testing are levied on the uncertainties of various wavefront-error-related quantities rather than on the wavefront errors themselves. This paper also describes the methodology, based on Monte Carlo simulations of the wavefront-sensing analysis of focus-sweep data, used to establish the uncertainties of the wavefront-error maps.

image analysis↗

NASA NTRS1983

Axial vane-type swirler performance characteristics

The performance of an axial vane-type swirler was investigated to aid in computer modeling of gas turbine combustor flowfields and in evaluation of turbulence models for swirling confined jet flow. The swirler studied is annular with a hub-to-swirler diameter ratio of 0.25 and ten adjustable vanes of pitch-to-chord ratio 0.68. Measurements of time-mean axial, radial, and tangential velocities were made at the swirler exit plane using a five-hole pitot probe technique with computer data reduction. Nondimensionalized velocities from both radial and azimuthal traverses are tabulated and plotted for a range of swirl vane angles phi from 0 to 70 degrees. A study was done of idealized exit-plane velocity profiles relating the swirl numbers S and S' to the ratio of maximum swirl and axial velocities for each idealized case, and comparing the idealized swirl numbers with ones calculated from measured profiles.

Sander, G. F.↗

NASA NTRS2013

Aerodynamic Measurements of a Variable-Speed Power-Turbine Blade Section in a Transonic Turbine Cascade at Low Inlet Turbulence

Aerodynamic measurements obtained in a transonic linear cascade were used to assess the impact of large incidence angle and Reynolds number variations on the 3-D flow field and midspan loss and turning of a 2-D section of a variable-speed power-turbine (VSPT) rotor blade. Steady-state data were obtained for ten incidence angles ranging from +15.8 deg to −51.0 deg. At each angle, data were acquired at five flow conditions with the exit Reynolds number (based on axial chord) varying over an order-of-magnitude from 2.12×10(exp 5) to 2.12×10(exp 6). Data were obtained at the design exit Mach number of 0.72 and at a reduced exit Mach number of 0.35 as required to achieve the lowest Reynolds number. Midspan total-pressure and exit flow angle data were acquired using a five-hole pitch/yaw probe surveyed on a plane located 7.0 percent axial chord downstream of the blade trailing edge plane. The survey spanned three blade passages. Additionally, three-dimensional half-span flow fields were examined with additional probe survey data acquired at 26 span locations for two key incidence angles of +5.8 deg and −36.7 deg. Survey data near the endwall were acquired with a three-hole boundary-layer probe. The data were integrated to determine average exit total-pressure and flow angle as functions of incidence and flow conditions. The data set also includes blade static pressures measured on four spanwise planes and endwall static pressures. Tests were conducted in the NASA Glenn Transonic Turbine Blade Cascade Facility. The measurements reflect strong secondary flows associated with the high aerodynamic loading levels at large positive incidence angles and an increase in loss levels with decreasing Reynolds number. The secondary flows decrease with negative incidence as the blade becomes unloaded. Transitional flow is admitted in this low inlet turbulence dataset, making it a challenging CFD test case. The dataset will be used to advance understanding of the aerodynamic challenges associated with maintaining efficient power turbine operation over a wide shaft-speed range. deg

Flegel-McVetta, Ashlie B.↗

NASA NTRS2014

Aerodynamic Measurements of a Variable-Speed Power-Turbine Blade Section in a Transonic Turbine Cascade

The purpose of this thesis is to document the impact of incidence angle and Reynolds number variations on the three-dimensional flow field and midspan loss and turning of a two-dimensional section of a variable-speed power-turbine (VSPT) rotor blade. Aerodynamic measurements were obtained in a transonic linear cascade at NASA Glenn Research Center in Cleveland, Ohio. Steady-state data were obtained for 10 incidence angles ranging from +15.8deg to -51.0deg. At each angle, data were acquired at five flow conditions with the exit Reynolds number (based on axial chord) varying over an order-of-magnitude from 2.12×105 to 2.12×106. Data were obtained at the design exit Mach number of 0.72 and at a reduced exit Mach number of 0.35 as required to achieve the lowest Reynolds number. Midspan tota lpressure and exit flow angle data were acquired using a five-hole pitch/yaw probe surveyed on a plane located 7.0 percent axial-chord downstream of the blade trailing edge plane. The survey spanned three blade passages. Additionally, three-dimensional half-span flow fields were examined with additional probe survey data acquired at 26 span locations for two key incidence angles of +5.8deg and -36.7deg. Survey data near the endwall were acquired with a three-hole boundary-layer probe. The data were integrated to determine average exit total-pressure and flow angle as functions of incidence and flow conditions. The data set also includes blade static pressures measured on four spanwise planes and endwall static pressures.

Flegel, Ashlie B.↗