Rocket engine evaluation of protective coatings.
Refractory metal coatings protective capabilities in rocket engine propulsive environment evaluated for effectiveness
Balling, N. R.↗
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Formal Validation of Fault Management Design Solutions
The work presented in this paper describes an approach used to develop SysML modeling patterns to express the behavior of fault protection, test the model's logic by performing fault injection simulations, and verify the fault protection system's logical design via model checking. A representative example, using a subset of the fault protection design for the Soil Moisture Active-Passive (SMAP) system, was modeled with SysML State Machines and JavaScript as Action Language. The SysML model captures interactions between relevant system components and system behavior abstractions (mode managers, error monitors, fault protection engine, and devices/switches). Development of a method to implement verifiable and lightweight executable fault protection models enables future missions to have access to larger fault test domains and verifiable design patterns. A tool-chain to transform the SysML model to jpf-Statechart compliant Java code and then verify the generated code via model checking was established. Conclusions and lessons learned from this work are also described, as well as potential avenues for further research and development.
Statechart↗
A Model-Based Architecture for a Small Flexible Fault Protection System
In this paper we will give a brief overview of how different missions implemented the fault protection application and the improvements along the way. We will then propose an architecture that supports the direct implementation of state-chart models into flight code. These state-chart models can be used to formally and naturally specify the behavior of all the major fault protection components - monitors, fault protection engine, and fault responses. The goal is a flexible, light-weight implementation of a traditional fault protection software system that is inexpensive to implement, reliable and understandable for both system and software developers.
Watney, Garth↗
A Dynamic Testing Approach for Particulate Erosion–Corrosion for Gas Turbine Coatings
Particle interactions in gas turbine engines can be multicomponent, complex phenomena leading to the degradation of thermal (TBCs) and environmental barrier coatings (EBCs) meant to protect engine components. Ingestion of particles into the engine can lead to recession of coatings due to particle erosion. Similarly, these same particles can become molten, adhere to coatings and result in thermochemical corrosion of coating materials. Particle erosion testing is often carried out where the particles are injected into a gas stream, accelerated within a nozzle, and impinge on sample. Conversely, most molten particle corrosion testing is often done in static laboratory furnaces, which does not capture the dynamic nature of deposition in application. Nevertheless, these damage mechanisms are often tested separately and no single standard exists to test both erosive and corrosive particle interactions with coating materials under relevant operating conditions for gas turbine engines. Understanding the synergies of particle interactions in engines is crucial in determining operating lifetimes of potential coating materials. Such considerations emphasize the need for realistic approaches in standardizing particle interaction testing in combustion environments. The current study outlines initial efforts at NASA Glenn’s Erosion Burner Rig Facility in improving dynamic erosion/corrosion testing methods by assessing the durability of state-of-the-art (SOA) TBC material 7 wt.% yttria stabilized zirconia (7YSZ) as a function of particle deposition rate, burner temperature, and particle size. Calibration data to determine particle deposition rate will be presented, and mass and optical profilometry measurements were utilized to estimate mass/volume loss versus deposition per increment of particulate used over time. Electron microscopy analyses were then carried out to assess coating damage after testing.
TBC↗
A Dynamic Testing Approach for Particulate Erosion–Corrosion for Gas Turbine Coatings
Particle interactions in gas turbine engines can be multicomponent, complex phenomena leading to the degradation of thermal (TBCs) and environmental barrier coatings (EBCs) meant to protect engine components. Ingestion of particles into the engine can lead to recession of coatings due to particle erosion. Similarly, these same particles can become molten, adhere to coatings and result in thermochemical corrosion of coating materials. Particle erosion testing is often carried out where the particles are injected into a gas stream, accelerated within a nozzle, and impinge on sample. Conversely, most molten particle corrosion testing is often done in static laboratory furnaces, which does not capture the dynamic nature of deposition in application. Nevertheless, these damage mechanisms are often tested separately and no single standard exists to test both erosive and corrosive particle interactions with coating materials under relevant operating conditions for gas turbine engines. Understanding the synergies of particle interactions in engines is crucial in determining operating lifetimes of potential coating materials. Such considerations emphasize the need for realistic approaches in standardizing particle interaction testing in combustion environments. The current study outlines initial efforts at NASA Glenn’s Erosion Burner Rig Facility in improving dynamic erosion/corrosion testing methods by assessing the durability of state-of-the-art (SOA) TBC material 7 wt.% yttria stabilized zirconia (7YSZ) as a function of particle deposition rate, burner temperature, and particle size. Calibration data to determine particle deposition rate will be presented, and mass and optical profilometry measurements were utilized to estimate mass/volume loss versus deposition per increment of particulate used over time. Electron microscopy analyses were then carried out to assess coating damage after testing.
TBC↗
A Dynamic Testing Approach for Particulate Erosion–Corrosion for Gas Turbine Coatings
Particle interactions in gas turbine engines can be multicomponent, complex phenomena leading to the degradation of thermal (TBCs) and environmental barrier coatings (EBCs) meant to protect engine components. Ingestion of particles into the engine can lead to recession of coatings due to particle erosion. Similarly, these same particles can become molten, adhere to coatings and result in thermochemical corrosion of coating materials. Particle erosion testing is often carried out where the particles are injected into a gas stream, accelerated within a nozzle, and impinge on sample. Conversely, most molten particle corrosion testing is often done in static laboratory furnaces, which does not capture the dynamic nature of deposition in application. Nevertheless, these damage mechanisms are often tested separately and no single standard exists to test both erosive and corrosive particle interactions with coating materials under relevant operating conditions for gas turbine engines. Understanding the synergies of particle interactions in engines is crucial in determining operating lifetimes of potential coating materials. Such considerations emphasize the need for realistic approaches in standardizing particle interaction testing in combustion environments. The current study outlines initial efforts at NASA Glenn’s Erosion Burner Rig Facility in improving dynamic erosion/corrosion testing methods by assessing the durability of state-of-the-art (SOA) TBC material 7 wt.% yttria stabilized zirconia (7YSZ) as a function of particle deposition rate, burner temperature, and particle size. Calibration data to determine particle deposition rate will be presented, and mass and optical profilometry measurements were utilized to estimate mass/volume loss versus deposition per increment of particulate used over time. Electron microscopy analyses were then carried out to assess coating damage after testing.
burner rig↗
Therma1 Conductivity and Durability of Advanced Thermal Barrier Coatings
Thermal barrier coatings (TBCs) will play a crucial role in advanced gas turbine engines because of their ability to further increase engine operating temperature and reduce cooling, thus helping to achieve engine emission and efficiency goals. Future TBCs must be designed with increased phase stability, lower thermal conductivity, and improved sintering and thermal stress resistance in order to effectively protect engine hot-section components. Advanced low conductivity TBCs are being developed at NASA by incorporating multi-component oxide dopants into zirconia-yttria or hafnia-yttria to promote the formation of thermodynamically stable defect clusters within the coating structures. This presentation will primarily focus on thermal conductivity and durability of the novel defect cluster thermal barrier coatings for turbine airfoil and combustor applications, determined by a unique CO2 laser heat-flux approach. The laser heat-flux testing approach emphasizes the real-time monitoring and assessment of the coating thermal conductivity under simulated engine temperature and thermal gradient conditions. The conductivity increase due to coating sintering (and/or phase change) and the conductivity decrease due to coating delamination have been determined under steady-state, cyclic, uniform or non-uniform heat-flux conditions. The coating radiation flux resistance has been evaluated by varying coating thermal gradients, and also by using a laser-heated radiative-flux source. Advanced multi-component TBC systems have been shown to have significantly reduced thermal conductivity and improved high temperature stability due to the nano-sized, low mobility defect clusters associated with the paired rare earth dopant additions. The effect of oxide defect cluster dopants on coating thermal conductivity, thermal stability and furnace cyclic durability will also be discussed. The current low conductivity TBC systems have demonstrated long-term cyclic durability at very high temperatures which is far beyond the baseline ZrO2-Y2O3 capabilities.
Zhu, Dong-Ming↗
Analysis of Line Distance Elements for Various Ibr Controllers and System Conditions
The large-scale penetration of inverter-based resources in power systems has challenged protection engineers because of the different fault behaviors these sources provide compared to conventional generation systems. The main challenges include a low level of fault current magnitude, unpredictable angles of sequence currents, and lack of inertia that can lead to maloperation of conventional phasor-based protection elements. This paper presents a sensitivity analysis of transmission line distance protection elements during phase-to-ground and phase-to-phase faults for different inverter controllers and power system conditions. It also summarizes which line protection elements remain secure near IBR terminations and identifies the ones affected by the inverter-based response. The paper concludes by highlighting that regulating negative-sequence current injection during the fault aids correct protection decisions, but does not address the entire challenge. Finally, alternative protection elements to those affected by the inverter fault response are discussed.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Evaluation of a Reduced-Order Model for IBR Fault Response Representation via OEM Blackbox Models
This paper presents a fully implemented inverter reduced-order-model (ROM) in an EMT simulation (PSCAD) library component for direct user utilization in protection studies. The developed inverter ROM has the following features: Equivalent to a full inverter-based resource (IBR) inverter model with positive- and negative-sequence current formulation and representation. A Python script is developed to fully automate this process, including training data generation, ROM parameter training, updating parameters, and model verification and validation. The ROM is validated using both IEEE 2800-compliant and non-compliant OEM modes in a real-world system, building confidence of its usability by protection engineers.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Utility Experience with Inverter Based Resource Impacts on Transmission Protection
High penetration of inverter-based resources (IBR) can adversely affect the transmission protection schemes in the area. With the proliferation of IBRs, utilities are finding out that conventional protection schemes are not adequately equipped to protect the electric systems because the existing system has been designed based on the fault current response of conventional rotating-machine-based generators. In several cases, the available literature does not provide any clear solution for the issues when the protection scheme does not operate properly near IBRs. This report identifies various protection challenges due to IBRs that industry is facing, from the utility perspective. It includes a broad review of all challenges that system protection has experienced so far with high penetration of IBRs. Key issues have been identified based on a survey of different utility protection engineers. Finally, fault event recordings are shown to demonstrate some actual cases of mis-operations of relays near IBRs.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Directory of workers in the fire field
A directory was compiled to provide a list of workers engaged in fire research, their addresses and affiliations, and their principal fields of activity. The initial criteria for the selection of names for the directory are recent contributions to fire literature, teaching of subjects relevant to fire science, or participation in or support of fire research programs. With some exceptions, fire service personnel and fire protection engineers were excluded because directories already exist for these professionals. Also excluded are investigators engaged principally in studies of propulsion, combustion, and explosion phenomena, because these areas of study are somewhat aside from the main focus of fire research. For purposes of the directory, fire science is taken to be the body of knowledge, art, and skill related to the investigation, analysis, and interpretation of the phenomena of unwanted fires and the evaluation of materials methods, systems, and equipment related to fire safety, prevention, detection, and suppression.
Kuvshinoff, B. W.↗
The communications industry's requirements and interests
Of interest to the communications industry are the amplitude, waveshape, duration and frequency of lightning-originated voltage surges and transients on the communications network, including the distribution system and AC power supply circuits. The cloud-to-ground lightning discharge and its characteristics are thought to be most meaningful. Of specific interest are peak current, waveshape, number of flashes, strokes per flash, and zone of influence. Accurate and meaningful lightning data at the local level (telephone district office) is necessary for a decision on the appropriate protection level. In addition to lightning, the protection engineer must consider other factors such as: AC induction, switching surges, ground potential rise, soil resistivity, bonding and grounding techniques, shielding and isolation, and exposure of the telephone loop.
Wanaselja, O.↗
Fail-Safe Pressure Plug
Protective plug resists slowly built-up pressure or automatically releases itself if pressure rises suddenly. Seals out moisture at pressures ranging from 50 micrometers of mercury to 200 pounds per square inch. Designed to seal throat of 38 Reaction Control Thrusters on Space Shuttle protecting internal components from corrosion. Plug conforms to contour of nozzle throat, where O-ring forms pressure seal. After plug inserted, cover attached by use of cover-fitting assembly. Modified versions useful in protecting engines, pumps, reaction vessels, and other industrial equipment during shipment and maintenance.
Svejkovsky, Paul A.↗
SSME Propellant Path Leak Detection
The primary objective of this phase of the investigation is the experimental validation of techniques for detecting and analyzing propellant path external leaks which have a high probability of occurring on the SSME. The selection of candidate detection methods requires a good analytic model for leak plumes which would develop from external leaks and an understanding of radiation transfer through the leak plume. One advanced propellant path leak detection technique is obtained by using state-of-art technology of infrared (IR) thermal imaging systems combined with computer, digital image processing and expert systems for the engine protection. The feasibility of the IR leak plume detection will be evaluated on subscale simulated laboratory plumes to determine sensitivity, signal to noise, and general suitability for the application. The theoretical analysis was undertaken with the objective of developing and testing simple, easy-to-use models to predict the amount of radiation coming from a radiation source, background plate (BP), which can be absorbed, emitted and scattered by the gas leaks.
Roger Crawford↗
SSME Propellant Path Leak Detection
The complicated high-pressure cycle of the space shuttle main engine (SSME) propellant path provides many opportunities for external propellant path leaks while the engine is running. This mode of engine failure may be detected and analyzed with sufficient speed to save critical engine test hardware from destruction. The leaks indicate hardware failures which will damage or destroy an engine if undetected; therefore, detection of both cryogenic and hot gas leaks is the objective of this investigation. The primary objective of this phase of the investigation is the experimental validation of techniques for detecting and analyzing propellant path external leaks which have a high probability of occurring on the SSME. The selection of candidate detection methods requires a good analytic model for leak plumes which would develop from external leaks and an understanding of radiation transfer through the leak plume. One advanced propellant path leak detection technique is obtained by using state-of-the-art technology infrared (IR) thermal imaging systems combined with computer, digital image processing, and expert systems for the engine protection. The feasibility of IR leak plume detection is evaluated on subscale simulated laboratory plumes to determine sensitivity, signal to noise, and general suitability for the application.
Roger Crawford↗
Thermal Conductivity and Temperature Limits of Electron-Beam Physical-Vapor-Deposited ZrO2-7wt%Y2O3 Thermal Barrier Coating
The electron-beam physical-vapor-deposited (EB-PVD) ZrO2-7wt%Y2O3 thermal barrier coating has been widely used to protect engine hot section components in modem aircraft engines. Thermal conductivity and the conductivity increases due to sintering and phase changes are important coating design parameters. There is a need to characterize the coating thermal conductivity behavior and temperature limits, in order to potentially take full advantage of the coating capability. In addition, since the ZrO2-7wt%Y2O3 coating is often used as a baseline coating for the development of advanced lower thermal conductivity and higher temperature capability coatings, a thorough evaluation of the coating conductivity behavior at future higher engine operating temperatures will be useful for more accurately assessing the benefit gained from the new coating systems. In this study, thermal conductivity behavior of EB-PVD ZrO2-7wt%Y2O3 coating has been systematically investigated as a function of temperature (up to 2600 F) and time under steady-state and cyclic test conditions using a laser heat-flux technique. Thermal conductivity change kinetics were determined under realistic engine high temperature thermal gradient conditions, and correlated to the coating microstructural and phase changes. The thermal conductivity prediction models have been established in terms of heat flux, time, and testing temperatures.
Zhu, Dongming↗
Bayesian Framework For Bioburden Density Calculations To Perform Planetary Protection Probabilistic Risk Assessment
The planetary protection discipline aims to minimize the microbial contamination on spacecraft to prevent the inadvertent contamination of other planetary bodies, known as forward planetary protection (PP). Planetary protection probabilistic risk assessment (PRA) relies on two core methodologies-the contamination probability event tree analysis and statistical parameter estimation. Planetary protection engineers combine several techniques to estimate the bioburden present on spacecraft components. A direct assay to enumerate CFU (colony forming units) is the preferred methodology, but given a similar processing environment the bioburden present on certain components is inferred using: (1) a NASA defined bioburden estimate based upon the biological cleanliness of the manufacturing/assembly environment or (2) sampled data from a similar spacecraft component. The paper presents an empirical Bayesian framework to systematically treat bioburden estimation and its uncertainties on different levels starting with measurement procedures to combining different components to subsystems and whole spacecraft. It is shown that the Bayesian approach can effectively handle estimations and their uncertainties at different levels and produce a reliable estimate for bioburden to be used to evaluate the probability of contamination.
Seuylemezian, Arman↗
Space Shuttle Main Engine nozzle thermal protection system
Two of the three Space Shuttle Main Engine (SSME) nozzles are exposed to significant reentry aeroheating loads. To ensure reusability of the Nozzle Assembly, the nozzle primary structure must not exceed specific temperature limits. Due to the thermal, pressure, and dynamic flexing of the nozzle during a mission cycle, an appropriate insulating system must have significant flexibility. Recent missions have demonstrated nozzle reentry aeroheating rates and heat loads much higher than predictions, higher than the capability of the original insulating system. A new insulating system has been developed using similar materials in an aerodynamically 'smooth' shape to both reduce the incoming heating and increase radiation cooling.
Nordlund, R. M.↗