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NASA NTRS2003

Investigation of the Flow Physics Driving Stall-Side Flutter in Advanced Forward Swept Fan Designs

Flutter-free operation of advanced transonic fan designs continues to be a challenging task for the designers of aircraft engines. In order to meet the demands of increased performance and lighter weight, these modern fan designs usually feature low-aspect ratio shroudless rotor blade designs that make the task of achieving adequate flutter margin even more challenging for the aeroelastician. This is especially true for advanced forward swept designs that encompass an entirely new design space compared to previous experience. Fortunately, advances in unsteady computational fluid dynamic (CFD) techniques over the past decade now provide an analysis capability that can be used to quantitatively assess the aeroelastic characteristics of these next generation fans during the design cycle. For aeroelastic applications, Mississippi State University and NASA Glenn Research Center have developed the CFD code TURBO-AE. This code is a time-accurate three-dimensional Euler/Navier-Stokes unsteady flow solver developed for axial-flow turbomachinery that can model multiple blade rows undergoing harmonic oscillations with arbitrary interblade phase angles, i.e., nodal diameter patterns. Details of the code can be found in Chen et al. (1993, 1994), Bakhle et al. (1997, 1998), and Srivastava et al. (1999). To assess aeroelastic stability, the work-per-cycle from TURBO-AE is converted to the critical damping ratio since this value is more physically meaningful, with both the unsteady normal pressure and viscous shear forces included in the work-per-cycle calculation. If the total damping (aerodynamic plus mechanical) is negative, then the blade is unstable since it extracts energy from the flow field over the vibration cycle. TURBO-AE is an integral part of an aeroelastic design system being developed at Honeywell Engines, Systems & Services for flutter and forced response predictions, with test cases from development rig and engine tests being used to validate its predictive capability. A recent experimental program (Sanders et al., 2002) was aimed at providing the necessary unsteady aerodynamic and vibratory response data needed to validate TURBO-AE for fan flutter predictions. A comparison of numerical TURBO-AE simulations with the benchmark flutter data is given in Sanders et al. (2003), with the data used to guide the validation of the code and define best practices for performing accurate unsteady simulations. The agreement between the analyses and the predictions was quite remarkable, demonstrating the ability of the analysis to accurately model the unsteady flow processes driving stall-side flutter.

Sanders, Albert J.↗

NASA NTRS1989

Sliding seal materials for low heat rejection engines

Sliding friction coefficients and wear rates of promising piston seal materials were measured under temperature, environmental, velocity, and loading conditions that are representative of the low heat rejection (LHR) diesel engine environment. These materials included carbides, oxides, and nitrides. In addition, silicon nitride and partially stablized zirconia disks (cylinder liners) were ion-implanted with TiNi, Ni, Co, and Cr, and subsequently run against carbide pins (piston rings), with the objective of producing reduced friction via solid lubrication at elevated temperature. Friction and wear measurements were obtained using pin-on-disk laboratory experiments and a unique engine friction test rig. Unmodified ceramic sliding couples were characterized at all temperatures by friction coefficients of 0.24 and above during the pin-on-disk tests. The coefficient at 800 C in an oxidizing environment was reduced to below 0.1, for certain material combination, by the ion-implantation of TiNi or Co. This beneficial effect was found to derive from the lubricious Ti, Ni, and Co oxides. Similar results were demonstrated on the engine friction test rig at lower temperatures. The structural integrity and feasibility of engine application with the most promising material combination were demonstrated during a 30-hour single-cylinder, direct-injection diesel engine test.

Beaty, Kevin↗

NASA NTRS1996

Comparisons Between Unsteady Aerodynamic Events in a Gas Turbine Generator and an Identical Compressor Rig

Extensive testing done on a T55-L-712 turboshaft engine compressor in a compressor test rig is being followed by engine tests in progress as part of the Army Non-Recoverable Stall Program. Goals include a greater understanding of the gas turbine engine start cycle and compressor/engine operation in the regions 'beyond' the normal compressor stall line (rotating stall/surge). Rig steady state instrumentation consisted of 497 steady state pressure sensors and 153 temperature sensors. Engine instrumentation was placed in similar radial/axial locations and consists of 122 steady state pressure sensors and 65 temperature sensors. High response rig instrumentation consisted of 34 wall static pressure transducers. Rig and engine high response pressure transducers were located in the same axial/radial/circumferential locations in front of the first three stages. Additional engine high response instrumentation was placed in mach probes in front of the engine and on the compressor hub. This instrumentation allows for the generation of detailed stage characteristics, overall compressor mapping, and detailed analysis of dynamic compressor events.

Owen, A. Karl↗

NASA NTRS2000

New High-Temperature Turbine Seal Rig Fabricated

Current NASA program goals for aircraft engines and vehicle performance include reducing direct operating costs for commercial aircraft by 3 percent in large engines and 5 percent in regional engines, reducing engine fuel burn up to 10 percent, and reducing engine oxides of nitrogen emissions by more than 50 percent. Significant advancements in current gas turbine engines and engine components, such as seals, are required to meet these goals. Specifically, advanced seals have been identified as critical in meeting engine goals for specific fuel consumption, thrust-to-weight ratio, emissions, durability, and operating costs. In a direct effort to address and make progress toward these goals, researchers at the NASA Glenn Research Center at Lewis Field have developed a unique high-temperature, high-speed engine seal test rig to evaluate seals under the temperature, speed, and pressure conditions anticipated for next generation turbine engines. This new seal test rig has capabilities beyond those of any existing seal rigs. It can test air seals (i.e., labyrinth, brush, and new seal concepts) at temperatures of up to 1500 F and pressures up to 100 psid (even higher pressures are possible at lower temperatures), and at all surface speeds anticipated in future NASA (Ultra Efficient Engine Technology, UEET, and Integrated High-Performance Turbine Engine Technology, IHPTET) engine programs. In addition, seals can be tested offset from the rotor centerline, in the rotor runout condition, and with simulated mission profiles. Support for this new rig was provided by NASA Glenn, the U.S. Air Force, and the U.S. Army.

Delgado, Irebert R.↗

NASA NTRS1998

Optical Instrumentation for Temperature and Velocity Measurements in Rig Turbines

Non-intrusive optical measurement techniques have been examined in the context of developing robust instruments which can routinely yield data of engineering utility in high speed turbomachinery test rigs. The engineering requirements of such a measurement are presented. Of particular interest were approaches that provide both velocity and state-variable information in order to be able to completely characterize transonic flowfields. Consideration of all of the requirements lead to the selection of particle image velocimetry (PIV) for the approach to velocity measurement while laser induced fluorescence of oxygen (O2 LIF) appeared to offer the most promise for gas temperature measurement. A PIV system was developed and demonstrated on a transonic turbine stage in the MIT blowdown turbine facility. A comprehensive data set has been taken at one flow condition. Extensive calibration established the absolute accuracy of the velocity measurements to be 3-5 %. The O2 LIF proved less successful. Although accurate for low speed flows, vibrational freezing of O2 prevented useful measurements in the transonic, 300-600 K operating range of interest here.

Ceyhan, I.↗

NASA NTRS2001

New High-Temperature Turbine Seal Rig Installed

Current NASA program goals for aircraft engines and vehicle performance include reducing direct operating costs for commercial aircraft by 3 percent in large engines and 5 percent in regional engines, reducing engine fuel burn up to 10 percent, and reducing engine oxides of nitrogen emissions by more than 50 percent. Significant advancements in current gas turbine engines and engine components, such as seals, are required to meet these goals. Specifically, advanced seals have been identified as critical in meeting engine goals for specific fuel consumption, thrust-to-weight ratio, emissions, durability, and operating costs. In a direct effort to address and make progress toward these goals, researchers at the NASA Glenn Research Center have developed a unique high-temperature, high-speed engine seal test rig to evaluate seals under the temperature, speed, and pressure conditions anticipated for next-generation turbine engines. Newly installed, this seal test rig has capabilities beyond those of any existing seal rigs. It can test air seals (i.e., labyrinth, brush, and new seal concepts) at temperatures of up to 1500 F and pressures up to 100 psid (even higher pressures are possible at lower temperatures), and at all surface speeds anticipated in future NASA (Ultra-Efficient Engine Technology, UEET) and Integrated High-Performance Turbine Engine Technology (IHPTET) engine programs. In addition, seals can be tested offset from the rotor centerline, in the rotor runout condition, and with simulated mission profiles. Support for this new rig was provided by Glenn, the U.S. Air Force, and the U.S. Army.

Delgado, Irebert R.↗

NASA NTRS1993

Advanced Turbine Technology Applications Project (ATTAP)

The Advanced Turbine Technologies Application Project (ATTAP) is in the fifth year of a multiyear development program to bring the automotive gas turbine engine to a state at which industry can make commercialization decisions. Activities during the past year included reference powertrain design updates, test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, ceramic component rig testing, and test-bed engine fabrication and testing. Engine design and development included mechanical design, combustion system development, alternate aerodynamic flow testing, and controls development. Design activities included development of the ceramic gasifier turbine static structure, the ceramic gasifier rotor, and the ceramic power turbine rotor. Material characterization efforts included the testing and evaluation of five candidate high temperature ceramic materials. Ceramic component process development and fabrication, with the objective of approaching automotive volumes and costs, continued for the gasifier turbine rotor, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Engine and rig fabrication, testing, and development supported improvements in ceramic component technology. Total test time in 1992 amounted to 599 hours, of which 147 hours were engine testing and 452 were hot rig testing.

Source record↗

NASA NTRS1997

Design and Checkout of a High Speed Research Nozzle Evaluation Rig

The High Flow Jet Exit Rig (HFJER) was designed to provide simulated mixed flow turbojet engine exhaust for one- seventh scale models of advanced High Speed Research test nozzles. The new rig was designed to be used at NASA Lewis Research Center in the Nozzle Acoustic Test Rig and the 8x6 Supersonic Wind Tunnel. Capabilities were also designed to collect nozzle thrust measurement, aerodynamic measurements, and acoustic measurements when installed at the Nozzle Acoustic Test Rig. Simulated engine exhaust can be supplied from a high pressure air source at 33 pounds of air per second at 530 degrees Rankine and nozzle pressure ratios of 4.0. In addition, a combustion unit was designed from a J-58 aircraft engine burner to provide 20 pounds of air per second at 2000 degrees Rankine, also at nozzle pressure ratios of 4.0. These airflow capacities were designed to test High Speed Research nozzles with exhaust areas from eighteen square inches to twenty-two square inches. Nozzle inlet flow measurement is available through pressure and temperature sensors installed in the rig. Research instrumentation on High Speed Research nozzles is available with a maximum of 200 individual pressure and 100 individual temperature measurements. Checkout testing was performed in May 1997 with a 22 square inch ASME long radius flow nozzle. Checkout test results will be summarized and compared to the stated design goals.

Castner, Raymond S.↗

NASA NTRS1976

Pollution technology program, can-annular combustor engines

A Pollution Reduction Technology Program to develop and demonstrate the combustor technology necessary to reduce exhaust emissions for aircraft engines using can-annular combustors is described. The program consisted of design, fabrication, experimental rig testing and assessment of results and was conducted in three program elements. The combustor configurations of each program element represented increasing potential for meeting the 1979 Environmental Protection Agency (EPA) emission standards, while also representing increasing complexity and difficulty of development and adaptation to an operational engine. Experimental test rig results indicate that significant reductions were made to the emission levels of the baseline JT8D-17 combustor by concepts in all three program elements. One of the Element I single-stage combustors reduced carbon monoxide to a level near, and total unburned hydrocarbons (THC) and smoke to levels below the 1979 EPA standards with little or no improvement in oxides of nitrogen. The Element II two-stage advanced Vorbix (vortex burning and mixing) concept met the standard for THC and achieved significant reductions in CO and NOx relative to the baseline. Although the Element III prevaporized-premixed concept reduced high power NOx below the Element II results, there was no improvement to the integrated EPA parameter relative to the Vorbix combustor.

Roberts, R.↗

NASA NTRS2008

An Adaptive Instability Suppression Controls Method for Aircraft Gas Turbine Engine Combustors

An adaptive controls method for instability suppression in gas turbine engine combustors has been developed and successfully tested with a realistic aircraft engine combustor rig. This testing was part of a program that demonstrated, for the first time, successful active combustor instability control in an aircraft gas turbine engine-like environment. The controls method is called Adaptive Sliding Phasor Averaged Control. Testing of the control method has been conducted in an experimental rig with different configurations designed to simulate combustors with instabilities of about 530 and 315 Hz. Results demonstrate the effectiveness of this method in suppressing combustor instabilities. In addition, a dramatic improvement in suppression of the instability was achieved by focusing control on the second harmonic of the instability. This is believed to be due to a phenomena discovered and reported earlier, the so called Intra-Harmonic Coupling. These results may have implications for future research in combustor instability control.

Kopasakis, George↗

NASA NTRS2016

Environmental Barrier Coatings for Ceramic Matrix Composites - An Overview

Ceramic Matrix Composites (CMCs) are increasingly being considered as structural materials for advanced power generation equipment. Broadly speaking the two classes of materials are oxide-based CMCs and non-oxide based CMCs. The non-oxide CMCs are primarily silicon-based. Under conditions prevalent in the gas turbine hot section the water vapor formed in the combustion of gaseous or liquid hydrocarbons reacts with the surface-SiO2 to form volatile products. Progressive surface recession of the SiC-SiC CMC component, strength loss as a result of wall thinning and chemical changes in the component occur, which leads to the loss of structural integrity and mechanical strength and becomes life limiting to the equipment in service. The solutions pursued to improve the life of SiC-SiC CMCs include the incorporation of an external barrier coating to provide surface protection to the CMC substrate. The coating system has become known as an Environmental Barrier Coating (EBC). The relevant early coatings work was focused on coatings for corrosion protection of silicon-based monolithic ceramics operating under severely corrosive conditions. The development of EBCs for gas turbine hot section components was built on the early work for silicon-based monolithics. The first generation EBC is a three-layer coating, which in its simplest configuration consists of a silicon (Si) base coat applied on top of the CMC, a barium-strontium-aluminosilicate (BSAS) surface coat resistant to water vapor attack, and a mullite-based intermediate coating layer between the Si base coat and BSAS top coat. This system can be represented as Si-Mullite-BSAS. While this baseline EBC presented a significant improvement over the uncoated SiC-SiC CMC, for the very long durations of 3-4 years or more expected for industrial operation further improvements in coating durability are desirable. Also, for very demanding applications with higher component temperatures but shorter service lives more rugged EBCs will be necessary. A second generation of EBCs incorporates rare earth silicates which have extremely favorable resistance against environmental attack and a higher temperature capability. Performance data for this class of EBCs is more limited and especially field data are not as extensive as for the first generation EBCs. Extensive laboratory, rig and engine testing, including testing of EBC coated SiC-SiC CMCs in actual field applications is in progress. The development of next generation EBCs with even higher temperature capability than the second generation EBC is also underway. This paper will discuss the current status of EBC technology and future direction based on literature survey.

Laboratory↗

NASA NTRS1988

AGT (Advanced Gas Turbine) technology project

An overall summary documentation is provided for the Advanced Gas Turbine Technology Project conducted by the Allison Gas Turbine Division of General Motors. This advanced, high risk work was initiated in October 1979 under charter from the U.S. Congress to promote an engine for transportation that would provide an alternate to reciprocating spark ignition (SI) engines for the U.S. automotive industry and simultaneously establish the feasibility of advanced ceramic materials for hot section components to be used in an automotive gas turbine. As this program evolved, dictates of available funding, Government charter, and technical developments caused program emphases to focus on the development and demonstration of the ceramic turbine hot section and away from the development of engine and powertrain technologies and subsequent vehicular demonstrations. Program technical performance concluded in June 1987. The AGT 100 program successfully achieved project objectives with significant technology advances. Specific AGT 100 program achievements are: (1) Ceramic component feasibility for use in gas turbine engines has been demonstrated; (2) A new, 100 hp engine was designed, fabricated, and tested for 572 hour at operating temperatures to 2200 F, uncooled; (3) Statistical design methodology has been applied and correlated to experimental data acquired from over 5500 hour of rig and engine testing; (4) Ceramic component processing capability has progressed from a rudimentary level able to fabricate simple parts to a sophisticated level able to provide complex geometries such as rotors and scrolls; (5) Required improvements for monolithic and composite ceramic gas turbine components to meet automotive reliability, performance, and cost goals have been identified; (6) The combustor design demonstrated lower emissions than 1986 Federal Standards on methanol, JP-5, and diesel fuel. Thus, the potential for meeting emission standards and multifuel capability has been initiated; (7) Small turbine engine aerodynamic and mechanical design capability has been initiated; and (8) An infrastructure of manpower, facilities, materials, and fabrication capabilities has been established which is available for continued development of ceramic component technology in gas turbine and other heat engines.

Source record↗

NASA NTRS2010

Drive Rig Mufflers for Model Scale Engine Acoustic Testing

Testing of air breathing propulsion systems in the 9x15 foot wind tunnel at NASA Glenn Research Center depends on compressed air turbines for power. The drive rig turbines exhaust directly to the wind tunnel test section, and have been found to produce significant unwanted noise that reduces the quality of the acoustic measurements of the model being tested. In order to mitigate this acoustic contamination, a muffler can be attached downstream of the drive rig turbine. The modern engine designs currently being tested produce much less noise than traditional engines, and consequently a lower noise floor is required of the facility. An acoustic test of a muffler designed to mitigate this extraneous noise is presented, and a noise reduction of 8 dB between 700 Hz and 20 kHz was documented, significantly improving the quality of acoustic measurements in the facility.

Stephens, David↗

NASA NTRS2018

DGEN Aeropropulsion Research Turbofan (DART): Lossless Projection of Measured Engine Noise Spectra to a 1-Foot-Radius Arc

Baseline noise and aerodynamic data have been acquired for the DGEN Aeropropulsion Research Turbofan (DART) test rig. The DART is a fully-mobile engine test rig featuring a DGEN380 geared turbofan producing approximately 500 lbs. of thrust at sea level and a self-contained control room. Baseline noise data were acquired using 5 microphone arrays, varying distance, configuration, and angle to reflect the measurement locations at several other test facilities. Noise data were acquired at one array location on each test day to establish the repeatability of the measurements. The noise data from the different arrays is analyzed to show the limitations of projecting the results to a common radius when the noise sources are distributed and the measurement location is not in the geometric far-field.

Noise↗

NASA NTRS1999

Advances in Thin Film Thermocouple Durability Under High Temperature and Pressure Testing Conditions

Thin film thermocouples for measuring material surface temperature have been previously demonstrated on several material systems and in various hostile test environments. A well-developed thin film fabrication procedure utilizing shadow masking for patterning the sensors elements had produced thin films with sufficient durability for applications in high temperature and pressure environments that exist in air-breathing and hydrogen-fueled burner rig and engine test facilities. However, while shadow masking had been a reliable method for specimens with flat and gently curved surfaces, it had not been consistently reliable for use on test components with sharp contours. This work reports on the feasibility of utilizing photolithography processing for patterning thin film thermocouples. Because this patterning process required changes in the thin film deposition process from that developed for shadow masking, the effect of these changes on thin film adherence during burner rig testing was evaluated. In addition to the results of changing the patterning method, the effects on thin film adherence of other processes used in the thin film fabrication procedure is also presented.

Martin, Lisa C.↗

NASA NTRS1977

Application of differential similarity to finding nondimensional groups important in tests of cooled engine components

The method of differential similarity is applied to the partial differential equations and boundary conditions which govern the temperature, velocity, and pressure fields in the flowing gases and the solid stationary components in air-cooled engines. This procedure yields the nondimensional groups which must have the same value in both the test rig and the engine to produce similarity between the test results and the engine performance. These results guide the experimentalist in the design and selection of test equipment that properly scales quantities to actual engine conditions. They also provide a firm fundamental foundation for substantiation of previous similarity analyses which employed heuristic, physical reasoning arguments to arrive at the nondimensional groups.

Sucec, J.↗

NASA NTRS2007

Computational Modeling Develops Ultra-Hard Steel

Glenn Research Center's Mechanical Components Branch developed a spiral bevel or face gear test rig for testing thermal behavior, surface fatigue, strain, vibration, and noise; a full-scale, 500-horsepower helicopter main-rotor transmission testing stand; a gear rig that allows fundamental studies of the dynamic behavior of gear systems and gear noise; and a high-speed helical gear test for analyzing thermal behavior for rotorcraft. The test rig provides accelerated fatigue life testing for standard spur gears at speeds of up to 10,000 rotations per minute. The test rig enables engineers to investigate the effects of materials, heat treat, shot peen, lubricants, and other factors on the gear's performance. QuesTek Innovations LLC, based in Evanston, Illinois, recently developed a carburized, martensitic gear steel with an ultra-hard case using its computational design methodology, but needed to verify surface fatigue, lifecycle performance, and overall reliability. The Battelle Memorial Institute introduced the company to researchers at Glenn's Mechanical Components Branch and facilitated a partnership allowing researchers at the NASA Center to conduct spur gear fatigue testing for the company. Testing revealed that QuesTek's gear steel outperforms the current state-of-the-art alloys used for aviation gears in contact fatigue by almost 300 percent. With the confidence and credibility provided by the NASA testing, QuesTek is commercializing two new steel alloys. Uses for this new class of steel are limitless in areas that demand exceptional strength for high throughput applications.

Source record↗

NASA NTRS1978

Reduction of aircraft gas turbine engine pollutant emissions

To accomplish simultaneous reduction of unburned hydrocarbons, carbon monoxide, and oxides of nitrogen, required major modifications to the combustor. The modification most commonly used was a staged combustion technique. While these designs are more complicated than production combustors, no insurmountable operational difficulties were encountered in either high pressure rig or engine tests which could not be resolved with additional normal development. The emission reduction results indicate that reductions in unburned hydrocarbons were sufficient to satisfy both near and far-termed EPA requirements. Although substantial reductions were observed, the success in achieving the CO and NOx standards was mixed and depended heavily on the engine/engine cycle on which it was employed. Technology for near term CO reduction was satisfactory or marginally satisfactory. Considerable doubt exists if this technology will satisfy all far-term requirements.

Diehl, L. A.↗