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NASA NTRS2016

Advanced Control Considerations for Turbofan Engine Design

This paper covers the application of a model-based engine control (MBEC) methodology featuring a self tuning on-board model for an aircraft turbofan engine simulation. The nonlinear engine model is capable of modeling realistic engine performance, allowing for a verification of the advanced control methodology over a wide range of operating points and life cycle conditions. The on-board model is a piece-wise linear model derived from the nonlinear engine model and updated using an optimal tuner Kalman Filter estimation routine, which enables the on-board model to self-tune to account for engine performance variations. MBEC is used here to show how advanced control architectures can improve efficiency during the design phase of a turbofan engine by reducing conservative operability margins. The operability margins that can be reduced, such as stall margin, can expand the engine design space and offer potential for efficiency improvements. Application of MBEC architecture to a nonlinear engine simulation is shown to reduce the thrust specific fuel consumption by approximately 1% over the baseline design, while maintaining safe operation of the engine across the flight envelope.

control↗

NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing," evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door, were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Ceramic Matrix Composites↗

NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Additive Manufacturing↗

NASA NTRS1976

Stirling cycle engine and refrigeration systems

A Stirling cycle heat engine is disclosed in which displacer motion is controlled as a function of the working fluid pressure P sub 1 and a substantially constant pressure P sub 0. The heat engine includes an auxiliary chamber at the constant pressure P sub 0. An end surface of a displacer piston is disposed in the auxiliary chamber. During the compression portion of the engine cycle when P sub 1 rises above P sub 0 the displacer forces the working fluid to pass from the cold chamber to the hot chamber of the engine. During the expansion portion of the engine cycle the heated working fluid in the hot chamber does work by pushing down on the engine's drive piston. As the working fluid pressure P sub 1 drops below P sub 0 the displacer forces most of the working fluid in the hot chamber to pass through the regenerator to the cold chamber. The engine is easily combinable with a refrigeration section to provide a refrigeration system in which the engine's single drive piston serves both the engine and the refrigeration section.

Higa, W. H.↗

NASA NTRS1979

The gate studies: Assessing the potential of future small general aviation turbine engines

Four studies were completed that explore the opportunities for future General Aviation turbine engines (GATE) in the 150-1000 SHP class. These studies forecasted the potential impact of advanced technology turbine engines in the post-1988 market, identified important aircraft and missions, desirable engine sizes, engine performance, and cost goals. Parametric evaluations of various engine cycles, configurations, design features, and advanced technology elements defined baseline conceptual engines for each of the important missions identified by the market analysis. Both fixed-wing and helicopter aircraft, and turboshaft, turboprop, and turbofan engines were considered. Sizable performance gains (e.g., 20% SFC decrease), and large engine cost reductions of sufficient magnitude to challenge the reciprocating engine in the 300-500 SHP class were predicted.

Strack, W. C.↗

NASA NTRS1979

Advanced General Aviation Turbine Engine (GATE) study

The small engine technology requirements suitable for general aviation service in the 1987 to 1988 time frame were defined. The market analysis showed potential United States engines sales of 31,500 per year providing that the turbine engine sales price approaches current reciprocating engine prices. An optimum engine design was prepared for four categories of fixed wing aircraft and for rotary wing applications. A common core approach was derived from the optimum engines that maximizes engine commonality over the power spectrum with a projected price competitive with reciprocating piston engines. The advanced technology features reduced engine cost, approximately 50 percent compared with current technology.

Smith, R.↗

NASA NTRS1979

New opportunities for future small civil turbine engines - Overviewing the GATE studies

This paper presents an overview of four independent studies that explore the opportunities for future General Aviation Turbine Engines (GATE) in the 150-1000 SHP class. Detroit Diesel Allison, Garrett/AiResearch, Teledyne CAE, and Williams Research participated along with several airframers. These studies forecasted the potential impact of advanced technology turbine engines in the post-1988 market, identified important aircraft and missions, desirable engine sizes, engine performance and cost goals. Parametric evaluations of various engine cycles, configurations, design features, and advanced technology elements defined baseline conceptual engines for each of the important missions identified by the market analysis. Both fixed-wing and helicopter aircraft, and turboshaft, turboprop, and turbofan engines were considered. All four companies predicted sizable performance gains (e.g., 20% SFC decrease), and three predicted large engine cost reductions of sufficient magnitude to challenge the reciprocating engine in the 300-500 SHP class. Key technology areas were recommended for NASA support in order to realize these improvements.

Strack, W. C.↗

NASA NTRS1980

Orbit transfer vehicle engine study. Volume 2: Technical report

The orbit transfer vehicle (OTV) engine study provided parametric performance, engine programmatic, and cost data on the complete propulsive spectrum that is available for a variety of high energy, space maneuvering missions. Candidate OTV engines from the near term RL 10 (and its derivatives) to advanced high performance expander and staged combustion cycle engines were examined. The RL 10/RL 10 derivative performance, cost and schedule data were updated and provisions defined which would be necessary to accommodate extended low thrust operation. Parametric performance, weight, envelope, and cost data were generated for advanced expander and staged combustion OTV engine concepts. A prepoint design study was conducted to optimize thrust chamber geometry and cooling, engine cycle variations, and controls for an advanced expander engine. Operation at low thrust was defined for the advanced expander engine and the feasibility and design impact of kitting was investigated. An analysis of crew safety and mission reliability was conducted for both the staged combustion and advanced expander OTV engine candidates.

Source record↗

NASA NTRS1981

Low-thrust chemical rocket engine study

An analytical study evaluating thrust chamber cooling engine cycles and preliminary engine design for low thrust chemical rocket engines for orbit transfer vehicles is described. Oxygen/hydrogen, oxygen/methane, and oxygen/RP-1 engines with thrust levels from 444.8 N to 13345 N, and chamber pressures from 13.8 N/sq cm to 689.5 N/sq cm were evaluated. The physical and thermodynamic properties of the propellant theoretical performance data, and transport properties are documented. The thrust chamber cooling limits for regenerative/radiation and film/radiation cooling are defined and parametric heat transfer data presented. A conceptual evaluation of a number of engine cycles was performed and a 2224.1 N oxygen/hydrogen engine cycle configuration and a 2224.1 N oxygen/methane configuration chosen for preliminary engine design. Updated parametric engine data, engine design drawings, and an assessment of technology required are presented.

Shoji, J. M.↗

NASA NTRS1981

Interactive-graphic flowpath plotting for turbine engines

An engine cycle program capable of simulating the design and off-design performance of arbitrary turbine engines, and a computer code which, when used in conjunction with the cycle code, can predict the weight of the engines are described. A graphics subroutine was added to the code to enable the engineer to visualize the designed engine with more clarity by producing an overall view of the designed engine for output on a graphics device using IBM-370 graphics subroutines. In addition, with the engine drawn on a graphics screen, the program allows for the interactive user to make changes to the inputs to the code for the engine to be redrawn and reweighed. These improvements allow better use of the code in conjunction with the engine program.

Corban, R. R.↗

NASA NTRS1981

Conventional engine technology. Volume 3: Comparisons and future potential

The status of five conventional automobile engine technologies was assessed and the future potential for increasing fuel economy and reducing exhaust emission was discussed, using the 1980 EPA California emisions standards as a comparative basis. By 1986, the fuel economy of a uniform charge Otto engine with a three-way catalyst is expected to increase 10%, while vehicles with lean burn (fast burn) engines should show a 20% fuel economy increase. Although vehicles with stratified-charge engines and rotary engines are expected to improve, their fuel economy will remain inferior to the other engine types. When adequate NO emissions control methods are implemented to meet the EPA requirements, vehicles with prechamber diesel engines are expected to yield a fuel economy advantage of about 15%. While successful introduction of direct injection diesel engine technology will provide a fuel savings of 30 to 35%, the planned regulation of exhaust particulates could seriously hinder this technology, because it is expected that only the smallest diesel engine vehicles could meet the proposed particulate requirements.

Dowdy, M. W.↗

NASA NTRS1982

A conceptual study of the potential for automotive-derived and free-piston Stirling engines in 30- to 400-kilowatt stationary power applications

The technical feasibility of applying automotive-derived kinematic and free-piston Stirling engine concepts for stationary applications was explored. Automotive-derived engines offer cost advantages by providing a mature and developd engine technology base with downrating and parts commonality options for specific applications. Two engine sizes (30 and 400 kW), two Stirling engine configurations (kinematic and free-piston), and two output systems (crankshaft and hydraulic pump) were studied. The study includes the influences of using either hydrogen or helium as the working gas. The first kinematic configuration selects an existing Stirling engine design from an automotive application and adapts it to stationary requirements. A 50,000-hour life requirement was established by downrating the engine to 40 kW and reducing auxiliary loads. Efficiency improvements were gained by selective material and geometric variations and peak brake efficiency of 36.8 percent using helium gas was achieved. The second design was a four-cylinder, 400 kW engine, utilizing a new output drive system known as the z-crank, which provides lower friction losses and variable stroke power control. Three different material and working gas combinations were considered. Brake efficiency levels varied from 40.5 percent to 45.6 percent. A 37.5 kW single-cycle, free-piston hydraulic output design was generated by scaling one cylinder of the original automotive engine and mating it to a counterbalanced reciprocal hydraulic pump. Metallic diaphragms were utilized to transmit power.

Vatsky, A.↗

NASA NTRS1983

Test results and description of a 1-kW free-piston Stirling engine with a dashpot load

A 1 kW (1.33 hp) single cylinder free piston Stirling engine was installed in the test facilities at the Lewis laboratory. The engine was designed specifically for research of the dynamics of its operation. A more complete description of the engine and its instrumentation is provided in a prior NASA paper TM-82999 by J. G. Schreiber. Initial tests at Lewis showed the power level and efficiency of the engine to be below design level. Tests were performed to help determine the specific problems in the engine causing the below design level performance. Modifications to engine hardware and to the facility where performed in an effort to bring the power output and efficiency to their design values. As finally configured the engine generated more than 1250 watts of output power at an engine efficiency greater than 32 percent. This report presents the tests performed to help determine the specific problems, the results if the problem was eliminated, the fix performed to the hardware, and the test results after the engine was tested. In cases where the fix did not cause the anticipated effects, a possible explanation is given.

Schreiber, J.↗

NASA NTRS1983

A simulation study of the low-speed characteristics of a light twin with an engine-out

Potential safety advantages provided by the two engines on a light twin aircraft are not realized in practice as evidenced by recent engine-failure accident statistics. These statistics showed twice the fatality rate from engine failure for twins as for single-engine aircraft. The statistics showed also that one-half of the fatal engine-out accidents involved a stall. An improvement of the low-speed engine-out characteristics is, therefore, needed. An investigation of the engine-out characteristics of light twin-engine aircraft is currently being conducted as part of the comprehensive stall/spin program for general aviation aircraft. The present study is concerned with the first phase of this program. The primary objective of this study is to advance the understanding of the basic flight dynamics and piloting problems for an engine-out condition. An all-digital computer system was used in the conducted simulation study.

Stewart, E. C.↗

NASA NTRS1984

Advanced high temperature materials for the energy efficient automotive Stirling engine

The Stirling Engine is under investigated jointly by the Department of Energy and NASA Lewis as an alternative to the internal combustion engine for automotive applications. The Stirling Engine is an external combustion engine that offers the advantage of high fuel economy, low emissions, low noise, and low vibrations compared to current internal combustion automotive engines. The most critical component from a materials viewpoint is the heater head consisting of the cylinders, heating tubes, and regenerator housing. Materials requirements for the heater head include compatibility with hydrogen, resistance to hydrogen permeation, high temperature oxidation/corrosion resistance and high temperature creep-rupture and fatigue properties. A continuing supporting materials research and technology program has identified the wrought alloys CG-27 and 12RN72 and the cast alloys XF-818 and NASAUT 4G-A1 as candidate replacements for the cobalt containing alloys used in current prototype engines. Based on the materials research program in support of the automotive Stirling engine it is concluded that manufacture of the engine is feasible from low cost iron-base alloys rather than the cobalt alloys rather than the cobalt alloys used in prototype engines. This paper will present results of research that led to this conclusion.

Titran, R. H.↗

NASA NTRS1983

Test results and description of a 1 kW free-piston Stirling engine with a dashpot load

Schreiber, J.↗

NASA NTRS1984

Modernizing engine displays

The introduction of electronic fuel control to modern turbine engines has a number of advantages, which are related to an increase in engine performance and to a reduction or elimination of the problems associated with high angle of attack engine operation from the surface to 50,000 feet. If the appropriate engine display devices are available to the pilot, the fuel control system can provide a great amount of information. Some of the wealth of information available from modern fuel controls are discussed in this paper. The considered electronic engine control systems in their most recent forms are known as the Full Authority Digital Engine Control (FADEC) and the Digital Electronic Engine Control (DEEC). Attention is given to some details regarding the control systems, typical engine problems, the solution of problems with the aid of displays, engine displays in normal operation, an example display format, a multipage format, flight strategies, and hardware considerations.

Schneider, E. T.↗

NASA NTRS1985

Lightweight two-stroke cycle aircraft diesel engine technology enablement program, volume 1

An experimental Single Cylinder Test Engine Program is conducted to confirm the analytically projected performance of a two-stroke cycle diesel engine for aircraft applications. The test engine delivered 78kW indicated power from 1007cc displacement, operating at 3500 RPM on Schnuerle loop scavenged two-stroke cycle. Testing confirms the ability of a proposed 4-cylinder version of such an engine to reach the target power at altitude, in a highly turbocharged configuration. The experimental program defines all necessary parameters to permit design of a multicylinder engine for eventual flight applications; including injection system requirement, turbocharging, heat rejection, breathing, scavenging, and structural requirements. The multicylinder engine concept is configured to operate with an augmented turbocharger, but with no primary scavenge blower. The test program is oriented to provide a balanced turbocharger compressor to turbine power balance without an auxiliary scavenging system. Engine cylinder heat rejection to the ambient air has been significantly reduced and the minimum overall turbocharger efficiency required is within the range of commercially available turbochargers. Analytical studies and finite element modeling is made of insulated configurations of the engines - including both ceramic and metallic versions. A second generation test engine is designed based on current test results.

Freen, P. D.↗