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Fabrication of lightweight turbine components for M-1 engine oxidizer turbopump using electron beam welding for attaching sheet metal blades to discs and shrouds
The development of ceramic components for automobile gas turbine engines is described with attention given to the steady and unsteady thermal conditions the ceramics will experience, and their anti-corrosion and strain-resistant properties. The ceramics considered for use in the automobile turbines include hot-pressed Si3N4, reaction-sintered, isostatically pressed Si3N4, hot-pressed SiC, reaction-bonded SiC, and glass ceramics. Attention is given to the stress analysis of ceramic structures and the state of the art of ceramic structural technology is reviewed, emphasizing the use of ceramics for combustion chambers and ceramic shrouded turbomachinery (a fully ceramic impeller).
Results obtained from testing five performance builds (three vane cascades and two rotating rigs of the Energy Efficient Engine uncooled rig have established the uncooled aerodynamic efficiency of the high-pressure turbine at 91.1 percent. This efficiency level was attained by increasing the rim speed and annulus area (AN(2)), and by increasing the turbine reaction level. The increase in AN(2) resulted in a performance improvement of 1.15 percent. At the design point pressure ratio, the increased reaction level rig demonstrated an efficiency of 91.1 percent. The results of this program have verified the aerodynamic design assumptions established for the Energy Efficient Engine high-pressure turbine component.
Nickel-base superalloys are used in jet engine components such as disks, turbine blades, and vanes. Improvements in the fatigue behavior will allow the life to be extended or the payloads to be increased. The first part of the present investigation deals primarily with the effects of microstructural variations on the fatigue crack propagation (FCP) behavior of nickel-base alloys, while the second part is concerned with low-cycle fatigue (LCF) behavior of Ni base systems. Waspaloy at low temperature is considered, taking into account material heat treatment and test procedures, a composite plot of Waspaloy FCP data, Paris law fatigue crack propagation constants, monotonic tensile data, and overload FCP test results for Waspaloy. It is found that the FCP and overload behavior of nickel-base alloys may be markedly improved by heat treating. Attention is given to effects of cyclic deformation on microstructure and substructure, environmental damage, and an environmental/deformation model of high temperature LCF.
To study the heat transfer in ceramic coatings applied to the heated side of internally cooled hot section components of the gas turbine engine, a mathematical model is developed for the thermal response of plasma-sprayed ZrO2-Y2O3 ceramic materials with a Ni-Cr-AL-Y bond coat on a Rene 41 rod substrate subject to thermal cycling. This multilayered cylinder with temperature dependent thermal properties is heated in a cross-flow by a high velocity flame and then cooled by ambient air. Due to high temperature and high velocity of the flame, both gas radiation and forced convection are taken into consideration. Furthermore, the local turbulent heat transfer coefficient is employed which varies with angular position as well as the surface temperature. The transient two-dimensional (heat transfer along axial direction is neglected) temperature distribution of the composite cylinder is determined numerically.
Hot section components of aircraft gas turbine engines are subjected to severe thermal-structural loading conditions, especially during the start-up and take-off portions of the engine cycle. The most severe and damaging stresses and strains are those induced by the steep thermal gradients induced during the start-up transient. These transient stresses and strains are also the most difficult to predict, in part because the temperature gradients and distributions are not well known or predictable, and also because the cyclic elasto-viscoplastic behavior of the materials at these extremes of temperature and strain are not well known or predictable. One element of the structures program will develop improved time-varying thermal-mechanical load models for the entire engine mission cycle from start-up to shutdown. The thermal model refinements will be consistent with those required by the structural code including considerations of mesh-point density, strain concentrations, and thermal gradients. Models will be developed for the burner liner, turbine vane and turbine blade.
The objective of the Elevated Temperature Crack Growth Program is to evaluate proposed nonlinear fracture mechanics methods for application to hot section components of aircraft gas turbine engines. Progress during the past year included linear-elastic fracture mechanics data reduction on nonlinear crack growth rate data on Alloy 718. The bulk of the analytical work centered on thermal gradient problems and proposed fracture mechanics parameters. Good correlation of thermal gradient experimental displacement data and finite element prediction was obtained.
The technological problems in which heat transfer research is required are briefly reviewed, discussing the role of the government laboratory in this research. The Hot Section Technology Program at NASA Lewis is addressed as an example. A building-block approach to turbine aerothermal research is shown, as is an interactive computational/experimental synergism and an interdisciplinary research methodology for life prediction of turbine engine hot-section components. The main issues for government laboratories as organizers and focusers in this area of research are listed, and challenges and opportunities for the future are indicated.
Hot-section components of aircraft gas turbine engines are subjected to severe thermal structural loading conditions, especially during the startup and takeoff portions of the engine cycle. The most severe and damaging stresses and strains are those induced by the steep thermal gradients induced during the startup transient. These transient stresses and strains are also the most difficult to predict, in part because the temperature gradients and distributions are not well known or readily predictable and, in part, because the cyclic elastic-viscoplastic behavior of the materials at these extremes of temperature and strain are not well known or readily predictable. A broad spectrum of structures related technology programs is underway to address these deficiencies at the basic as well as the applied level. The three key program elements in the HOST structural analysis program are computations, constitutive modeling, and experiments for each research activity. Also shown are tables summarizing each of the activities.
A study was conducted to identify component technology requirements for small, expendable gas turbine engines that would result in substantial improvements in performance and cost by the year 2000. A subsonic, 2600 nautical mile (4815 km) strategic cruise missile mission was selected for study. A baseline (state-of-the-art) engine and missile configuration were defined to evaluate the advanced technology engines. Two advanced technology engines were configured and evaluated using advanced component efficiencies and ceramic composite materials; a 22:1 overall pressure ratio, 3.85 bypass ratio twin-spool turbofan; and an 8:1 overall pressure, 3.66 bypass ratio, single-spool recuperated turbofan with 0.85 recuperator effectiveness. Results of mission analysis indicated a reduction in fuel burn of 38 and 47 percent compared to the baseline engine when using the advanced turbofan and recuperated turbofan, respectively. While use of either advanced engine resulted in approximately a 25 percent reduction in missile size, the unit life cycle (LCC) cost reduction of 56 percent for the advanced turbofan relative to the baseline engine gave it a decisive advantage over the recuperated turbofan with 47 percent LCC reduction. An additional range improvement of 10 percent results when using a 56 percent loaded carbon slurry fuel with either engine. These results can be realized only if significant progress is attained in the fields of solid lubricated bearings, small aerodynamic component performance, composite ceramic materials and integration of slurry fuels. A technology plan outlining prospective programs in these fields is presented.
The turbine component of a gas turbine engine is frequently subjected to extreme operation conditions associated with significant changes in mass flow, turbine inlet temperature, pressure and rotational speed. These off-design operation conditions significantly affect the flow deflection within the turbine stage, which consists of individual stator and rotor rows. As a result, the stage parameters representing the velocity diagram will change and affect the efficiency and performance of the stage and, thus, the turbine. A row-by-row calculation method is presented for predicting the performance behavior of turbines under extreme off-design conditions. The method is applied to a multistage turbine for which the off-design performance is calculated and compared with the measurement.
In a continuing investigation on developing and applying codes for prediction of performance of a turbine jet engine and its components with water ingestion during flight operation, including power settings, and flight altitudes and speed changes, an attempt was made to establish the effects of water ingestion through simulation of a generic high bypass ratio engine with a generic control. In view of the large effects arising in the air compression system and the prediffuser-combustor unit during water ingestion, attention was focused on those effects and the resulting changes in engine performance. Under all conditions of operation, whether ingestion is steady or not, it became evident that water ingestion causes a fan-compressor unit to operate in a time-dependent fashion with periodic features, particularly with respect to the state of water in the span and the film in the casing clearance space, at the exit of the machine. On the other hand, the aerodynamic performance of the unit may be considered as quasi-steady once the distribution of water has attained an equilibrium state with respect to its distribution and motion. For purposes of engine simulation, the performance maps for the generic fan-compressor unit were generated based on the attainment of a quasi-steady state (meaning steady except for long-period variations in performance) during ingestion and operation over a wide enough range of rotational speeds.
The topics covered include the following: community noise sources and noise control issues; noise components for turbine bypass turbojet engine (TBE) turbojet; engine cycle selection and noise; nozzle development schedule; NACA nozzle design; NACA nozzle test results; nearly fully mixed (NFM) nozzle design; noise versus aspiration rate; peak noise test results; nozzle test in the Low Speed Aeroacoustic Facility (LSAF); and Schlieren pictures of NACA nozzle.
This report includes: (1) a survey of the current methods for the measurement of surface temperature of ceramic materials suitable for use as hot section flowpath components in aircraft gas turbine engines; (2) analysis and selection of three sensing techniques with potential to extend surface temperature measurement capability beyond current limits; and (3) design, manufacture, and evaluation of the three selected techniques which include the following: platinum rhodium thin film thermocouple on alumina and mullite substrates; doped silicon carbide thin film thermocouple on silicon carbide, silicon nitride, and aluminum nitride substrates; and long and short wavelength radiation pyrometry on the substrates listed above plus yttria stabilized zirconia. Measurement of surface emittance of these materials at elevated temperature was included as part of this effort.
The scientific community has felt that ceramic matrix composite (CMC) materials possess more material damping than the superalloys used in the production of rocket engine turbomachinery turbine-end components. The purpose of this NASA/MFSC study is to quantify the damping in CMC's as compared to a typical super-alloy, Inconel 718. It was observed through testing of beam coupons and disk specimens that the CMC's do indeed possess more material damping than the baselined alloy Inconel 718.
Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.
Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. There is a need to characterize the fundamental sintering and fracture behavior of the current ZrO2-(7 to 8)wt%Y2O3 coating, in order to fully take advantage of the coating capability. In addition, a thorough evaluation of the coating behavior and temperature limits will be useful for more accurately assessing the benefit gained from future advanced coating systems. In this study, the sintering behavior of plasma-sprayed ZrO2-8wt%Y2O3 coatings was systematically investigated as a function of temperature and time using a dilatometer in the temperature range of 1200-1500 C. The coating sintering kinetics obtained by dilatometry were compared with the coating thermal conductivity increase kinetics, determined by a steady-state laser heat-flux testing approach, under high temperature and thermal gradient sintering conditions. The mode I, mode II, and mixed mode I-mode II fracture behavior of as-processed and sintering-annealed coatings was determined in asymmetric flexure loading at ambient and elevated temperatures in order to evaluate the coating sintering effects on the fracture envelope of K(sub I) versus K(sub II). The coating thermal conductivity cyclic response associated with the interface delamination of the coating systems under simulated engine heat-flux conditions will be discussed in conjunction with the sintering and fracture testing results.
Advanced materials and process approaches are described that have allowed NASA to develop five state-of-the-art silicon carbide (SiC) fiber-reinforced hybrid-SiC matrix composite systems that can operate under mechanical loading and oxidizing conditions for hundreds of hours at upper use temperatures from 1200 to 1450 C. Key data are presented that demonstrate the ability of these materials to meet the first-level property requirements for hot-section components in advanced gas turbine engines.