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NASA NTRS2019

NASA's Role in Gas Turbine Technology Development: Accelerating Technical Progress via Collaboration Between Academia, Industry, and Government Agencies

Given the maturity of the gas turbine engine since its invention and also considering the limited and flattened level of resources expected to be allocated for NASA aeronautics research and development, we ask the question are NASA technology investments still needed to enable future turbine engine-based propulsion systems? If so, what is NASA’s unique role to justify NASA’s investment? To address this topic, we will first review the accomplishments and the impact that NASA Glenn Research Center has made on turbine engine technologies over the last 78 years. Specifically, this paper discusses NASA’s role and contributions to turbine engine development, specific to both 1) NASA’s role in conducting experiments to understand flow physics and provide relevant benchmark validation experiments for Computational Fluid Dynamics (CFD) code development, validation, and assessment; and 2) the impact of technologies resulting from NASA collaborations with industry, academia, and other government agencies. Note that the scope of the discussion is limited to the NASA technology contributions with which the author was intimately associated, and does not represent the entirety of the NASA contributions to turbine engine technology. The specific research, development, and demonstrations discussed herein were selected to both 1) provide a comprehensive review and reference list of the technology and its impact, and 2) identify NASA’s unique role and highlight how NASA’s involvement resulted in additional benefit to the gas turbine engine community. Secondly, we will discuss current NASA collaborations that are in progress and provide a status of the results. Finally, we discuss the challenges anticipated for future turbine engine-based propulsion systems for civil aviation and identify potential opportunities for collaboration where NASA involvement would be beneficial. Ultimately, the gas turbine engine community will decide if NASA involvement is needed to contribute to the development of the design and analysis tools, databases, and technology demonstration programs to meet these challenges for future turbine engine-based propulsion systems.

Suder, Kenneth L.↗
NASA NTRS2015

Experimental and Finite Element Modeling of Near-Threshold Fatigue Crack Growth for the K-Decreasing Test Method

The experimental methods to determine near-threshold fatigue crack growth rate data are prescribed in ASTM standard E647. To produce near-threshold data at a constant stress ratio (R), the applied stress-intensity factor (K) is decreased as the crack grows based on a specified K-gradient. Consequently, as the fatigue crack growth rate threshold is approached and the crack tip opening displacement decreases, remote crack wake contact may occur due to the plastically deformed crack wake surfaces and shield the growing crack tip resulting in a reduced crack tip driving force and non-representative crack growth rate data. If such data are used to life a component, the evaluation could yield highly non-conservative predictions. Although this anomalous behavior has been shown to be affected by K-gradient, starting K level, residual stresses, environmental assisted cracking, specimen geometry, and material type, the specifications within the standard to avoid this effect are limited to a maximum fatigue crack growth rate and a suggestion for the K-gradient value. This paper provides parallel experimental and computational simulations for the K-decreasing method for two materials (an aluminum alloy, AA 2024-T3 and a titanium alloy, Ti 6-2-2-2-2) to aid in establishing clear understanding of appropriate testing requirements. These simulations investigate the effect of K-gradient, the maximum value of stress-intensity factor applied, and material type. A material independent term is developed to guide in the selection of appropriate test conditions for most engineering alloys. With the use of such a term, near-threshold fatigue crack growth rate tests can be performed at accelerated rates, near-threshold data can be acquired in days instead of weeks without having to establish testing criteria through trial and error, and these data can be acquired for most engineering materials, even those that are produced in relatively small product forms.

Smith, Stephen W.↗
NASA NTRS2005

Numerical Simulation of the RTA Combustion Rig

The Revolutionary Turbine Accelerator (RTA)/Turbine Based Combined Cycle (TBCC) project is investigating turbine-based propulsion systems for access to space. NASA Glenn Research Center and GE Aircraft Engines (GEAE) planned to develop a ground demonstrator engine for validation testing. The demonstrator (RTA-1) is a variable cycle, turbofan ramjet designed to transition from an augmented turbofan to a ramjet that produces the thrust required to accelerate the vehicle from Sea Level Static (SLS) to Mach 4. The RTA-1 is designed to accommodate a large variation in bypass ratios from sea level static to Mach 4 conditions. Key components of this engine are new, such as a nickel alloy fan, advanced trapped vortex combustor, a Variable Area Bypass Injector (VABI), radial flameholders, and multiple fueling zones. A means to mitigate risks to the RTA development program was the use of extensive component rig tests and computational fluid dynamics (CFD) analysis.

Davoudzadeh, Farhad↗
NASA NTRS2005

Reciprocating Feed System Development Status

The reciprocating feed system (RFS) is an alternative means of providing high pressure propellant flow at low cost and system mass, with high fail-operational reliability. The RFS functions by storing the liquid propellants in large, low-pressure tanks and then expelling each propellant through two or three small, high-pressure tanks. Each RFS tank is sequentially filled, pressurized, expelled, vented, and refilled so as to provide a constant, or variable, mass flow rate to the engine. This type of system is much lighter than a conventional pressure fed system in part due to the greatly reduced amount of inert tank weight. The delivered payload for an RFS is superior to that of conventional pressure fed systems for conditions of high total impulse and it is competitive with turbopump systems, up to approximately 2000 psi. An advanced version of the RFS uses autogenous pressurization and thrust augmentation to achieve higher performance. In this version, the pressurization gases are combusted in a small engine, thus making the pressurization system, in effect, part of the propulsion system. The RFS appears to be much less expensive than a turbopump system, due to reduced research and development cost and hardware cost, since it is basically composed of small high- pressure tanks, a pressurization system, and control valves. A major benefit is the high reliability fail-operational mode; in the event of a failure in one of the three tank-systems, it can operate on the two remaining tanks. Other benefits include variable pressure and flow rates, ease of engine restart in micro-gravity, and enhanced propellant acquisition and control under adverse acceleration conditions. We present a system mass analysis tool that accepts user inputs for various design and mission parameters and calculates such output values payload and vehicle weights for the conventional pressure fed system, the RFS, the Autogenous Pressurization Thrust Augmentation (APTA) RFS, and turbopump systems. Using this tool, a preliminary design of a representative crew exploration vehicle (CEV) has been considered. The design parameters selected for a representative system were modeled after the orbital maneuvering system (OMS) on the Shuttle Orbiter, with an increase of roughly a factor of ten in the delta- V capability and a greater thrust (30,000 lbs, vs. 12,000 lbs). Both storable and cryogenic propellants were considered. Results show that a RFS is a low mass alternative to conventional pressure fed systems, with a substantial increase in payload capability and that it is weight-competitive with turbopump systems at low engine pressure (a few hundred psi); at high engine pressures, the APTA RFS appears to offer the highest payload. We also present the status of the RFS test bed fabrication, assembly, and checkout. This test bed is designed to provide flow rates appropriate for engines in the roughly 10,000 to 30,000 lb thrust range.

Trewek, Mary↗
NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA Glenn Research Center

The Thermal Energy Conversion Branch at NASA Glenn Research Center is supporting the development of high-efficiency power convertors for use in radioisotope power systems (RPS). Significant progress was made toward such a system that utilized Stirling conversion during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was canceled in 2013 by the U.S. Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton design. The technology development contracts each consist of up to three phases: design, fabrication, and test. As of May 2018, all contracts have completed the design phase, and each underwent a design review with an independent review board. Three of the contracts are planned to execute the phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification (IV and V) at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, Glenn is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating several convertors from previous development projects, which have similarities and relevance to current contract designs. Four of these are flexure-bearing based and another six are gas bearing based. One of the flexure-bearing convertors has accumulated over 110,000 h of operation and holds the current record for maintenance-free heat-engine run time. Another flexure-bearing convertor was recently manually shut down after 105,620 h of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of run time on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent a launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Among the gas-bearing convertors, the longest running unit has accumulated over 70,000 h of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously for which the longest run time has reached 28,000 h.

Oriti, Salvatore M.↗
NASA NTRS1976

The development and flight test of an electronic integrated propulsion control system

Advanced technical features of the electronic integrated propulsion control system (IPCS) and flight evaluation tests of IPCS (F-111E with TF30-P-9 engines as test vehicle) are described. Nine baseline flight tests and 15 IPCS flight tests were conducted. Instrumentation, data acquisition and data processing systems, software maintenance procedures, flight test procedures, flight safety criteria, flight test results, and ground and flight testing of the aircraft system are described. Advantages conferred by IPCS include: faster accelerations (both gas generator and afterburner performance), better thrust and flight control, reduced flight idle thrust, reduced engine ground trim, extended service ceiling, automatic stall detection, and stall recovery detection.

Johnson, H. J.↗
NASA NTRS1973

Gas turbine engine fuel control

A variable orifice system is described that is responsive to compressor inlet pressure and temperature, compressor discharge pressure and rotational speed of a gas-turbine engine. It is incorporated into a hydraulic circuit that includes a zero gradient pump driven at a speed proportional to the speed of the engine. The resulting system provides control of fuel rate for starting, steady running, acceleration and deceleration under varying altitudes and flight speeds.

Gold, H. S.↗
NASA NTRS1980

Low thrust transfer of Large Space Systems

A study which defined an optimized low-thrust orbit transfer vehicle (OTV) is presented. The objectives of this NASA study were to (1) characterize missions which require or benefit from low-orbit transfer; (2) evaluate and compare candidate low-thrust liquid propulsion orbit transfer vehicle concepts; (3) determine propulsion/system characteristics which have the greatest influence on system suitability/capability; and (4) identify and describe propulsion technology requirements. A computerized optimization procedure was developed to determine the effect of thrust level and transients, number of burns, and payload structure material; a baseline hydrogen/oxygen low thrust OTV configured specifically for orbit transfer of large space systems was defined. Finally, the requirements for the engine for an optimized low thrust stage and the optimum vehicle for low acceleration missions were specified.

Ketchum, W. J.↗
NASA NTRS1987

NAECON 87; Proceedings of the IEEE National Aerospace and Electronics Conference, Dayton, OH, May 18-22, 1987. Volumes 1, 2, 3, & 4

The present conference discusses topics in VLSI components and their packaging, signal processing, uses of cartographic data, data transmission, advanced avionics architectures, fiber-optics, information control and display, image processing, airborne radar and fire control, navigation, air data, Kalman filtering, power generation and control, spacecraft power structures, aircraft flying qualities, flight management, fault-tolerant computer architectures, actuation technologies, self-repairing flight control system technology, multivariable control, stability and control methods, and AFTI/F-16 flight test reports. Also discussed are the ADA/JOVIAL language and its applications, software acquisition and testing, advanced software concepts, software management, computer graphics and visual systems softwear, ADA in embedded avionics, 16- and 32-bit architectures, voice interaction applications, human/machine systems analysis, human factors and AI, mental workloads and displays, pilot acceleration protection research, communications system technology, space communications, reliability and maintainability, managerial techniques, engineering management, EM compatibility and nuclear hardening, expert systems, AI language/knowledge representation, expert system implementation, machine vision/optical processing, and advanced AI concepts and architectures.

Avionics↗
NASA NTRS1990

Transonic Navier-Stokes solutions about a complex high-speed accelerator configuration

Three-dimensional transonic viscous flow computations are presented for a generic high-speed accelerator model which includes wing, body, fillets, and a no-flow through engine nacelle. Solutions are obtained from an algorithm for the compressible Navier-Stokes equations which incorporates an upwind-biased, flux-vector-splitting approach along with longitudinally-patched grids. Results are presented for fully turbulent flow assumptions and include correlations with wind tunnel data. A good quantitative agreement for the forebody surface pressure distribution is achieved between computations and the available wind-tunnel measurements at freestream Mach number equal to 0.9. Furthermore, it is demonstrated that the flow is stagnating around the boattail region due to separation from the aft-engine cowl lip.

Ghaffari, Farhad↗
NASA NTRS1991

Transonic Navier-Stokes solutions about a generic hypersonic configuration

Three-dimensional transonic viscous flow computations are presented for a generic high-speed accelerator model that includes wing, body, fillets, and a no-flow-through engine nacelle. Solutions are obtained from an algorithm for the compressible Navier-Stokes equations that incorporates an upwind-biased, flux-vector-splitting approach along with longitudinally patched grids. Results are presented for fully turbulent flow assumptions and include correlations with wind-tunnel data. A good quantitative agreement for the forebody surface pressure distribution is achieved between computations and the available wind-tunnel measurements at M∞ = 0.9. Furthermore, it is demonstrated that the flow is stagnating around the boattail region due to separation from the aft-engine cowl lip.

Hypersonic flows↗
NASA NTRS1991

Transonic Navier-Stokes Solutions about a Complex High-Speed Accelerator Configuration

Three dimensional transonic viscous flow computations are presented for a generic high-speed accelerator model which includes wing, body, filets,and a no-flow through engine nacelle. solutions are obtained from an algorithm for the compressible Navier-Stokes equations which incorporated an upwind-biased, flux-vector-splitting approach along with longitudinally-patched grids. Results are presented for fully turbulent flow assumptions and include correlations with wind tunnel data. A good quantitative agreement for the forebody surface pressure distribution is achieved between computations and the available wind-tunnel measurements at M(sub infinity) = 0.9. Furthermore, it is demonstrated that the flow is stagnating around the boattail region due to separation from the aft-engine cowl lip.

Ghaffari, F.↗
NASA NTRS1950

Preliminary Performance Data on General Electric Integrated Electronic Control Operating on J47 RX1-3 Turbojet Engine in NACA Altitude Wind Tunnel

Performance data obtained with recording oscillographs are presented to show the transient response of the General Electric Integrated Electronic Control operating on the J47 RXl-3 turbo-Jet engine over a range of altitudes from 10,000 to 45,000 feet and at ram pressure ratios of 1.03 and 1.4. These data represent the performance of the final control configuration developed after an investigation of the engine transient behavior in the NACA altitude wind tunnel. Oscillograph traces of controlled accelerations (throttle bursts),oontrolled decelerations (throttle chops), and controlled altitude starts are presented.

Darnold Blivas↗
NASA NTRS2006

Impact of the Columbia Supercomputer on NASA Space and Exploration Mission

NASA's 10,240-processor Columbia supercomputer gained worldwide recognition in 2004 for increasing the space agency's computing capability ten-fold, and enabling U.S. scientists and engineers to perform significant, breakthrough simulations. Columbia has amply demonstrated its capability to accelerate NASA's key missions, including space operations, exploration systems, science, and aeronautics. Columbia is part of an integrated high-end computing (HEC) environment comprised of massive storage and archive systems, high-speed networking, high-fidelity modeling and simulation tools, application performance optimization, and advanced data analysis and visualization. In this paper, we illustrate the impact Columbia is having on NASA's numerous space and exploration applications, such as the development of the Crew Exploration and Launch Vehicles (CEV/CLV), effects of long-duration human presence in space, and damage assessment and repair recommendations for remaining shuttle flights. We conclude by discussing HEC challenges that must be overcome to solve space-related science problems in the future.

Biswas, Rupak↗
NASA NTRS2014

An Experimental Study of Unconfined Hydrogen/Oxygen and Hydrogen/Air Explosions

Development tests are being conducted to characterize unconfined Hydrogen/air and Hydrogen/Oxygen blast characteristics. Most of the existing experiments for these types of explosions address contained explosions, like shock tubes. Therefore, the Hydrogen Unconfined Combustion Test Apparatus (HUCTA) has been developed as a gaseous combustion test device for determining the relationship between overpressure, impulse, and flame speed at various mixture ratios for unconfined reactions of hydrogen/oxygen and hydrogen/air. The system consists of a central platform plumbed to inject and mix component gasses into an attached translucent bag or balloon while monitoring hydrogen concentration. All tests are ignited with a spark with plans to introduce higher energy ignition sources in the future. Surrounding the platform are 9 blast pressure "Pencil" probes. Two high-speed cameras are used to observe flame speed within the combustion zone. The entire system is raised approx. 6 feet off the ground to remove any ground reflection from the measurements. As of this writing greater than 175 tests have been performed and include Design of Experiments test sets. Many of these early tests have used bags or balloons between approx. 340L and approx. 1850L to quantify the effect of gaseous mixture ratio on the properties of interest. All data acquisition is synchronized between the high-speed cameras, the probes, and the ignition system to observe flame and shock propagation. Successful attempts have been made to couple the pressure profile with the progress of the flame front within the combustion zone by placing a probe within the bag. Overpressure and impulse data obtained from these tests are used to anchor engineering analysis tools, CFD models and in the development of blast and fragment acceleration models.

Richardson, Erin↗
NASA NTRS2014

Influential Factors for Liquid Acquisition Device Screen Selection for Cryogenic Propulsion Systems

This paper presents the influential factors which govern screen selection for liquid acquisition devices (LADs) operating in microgravity conditions for future in-space cryogenic propulsion engines and cryogenic propellant depots. Space flight requirements, which include mass flow rate, acceleration level and direction, and thermal environment, dictate screen selection for a particular mission. The five influential factors include bubble point pressure, flow-through-screen pressure drop, wicking rate, screen compliance, and material compatibility. Governing equations and analytical models for these parameters are developed from first principles. A comprehensive survey of the historical data on coarser LAD meshes over four decades of work is conducted, and liquid hydrogen data for finer Dutch Twill meshes (325 x 2300, 450 x 2750, 510 x 3600) from recently concluded experiments is also presented to validate analytical models. Each of these parameters is measurable from ground based tests, making it facile to predict flight system performance. Therefore analytical models in this paper will be valuable for future LAD designs for both cryogenic and storable propulsion systems. Additionally, analysis will be given on the impact of the factors on liquid hydrogen systems.

Fuel Depot↗
NASA NTRSDate not supplied

Ion Velocity Characterization of the 12.5-kW Advanced Electric Propulsion System Engineering Hall Thruster

During development testing of the 12.5-kW Advanced Electric Propulsion System engineering unit Hall thruster, which is magnetically shielded, a laser-induced fluorescence test was performed. During this test, a third medium-energy ion population was found near the inner front pole cover in addition to two low-energy counter-streaming ion populations that were found in previous testing. This newly found ion population matched in characteristics with the single population found near the outer front pole cover. The measured characteristics of the medium-energy ions matched the behavior expected of them if they were energized by a plasma wave with magnetized electrons, such as a lower hybrid wave. Comparison of the data from this test to prior tests showed that this engineering thruster had very similar ion characteristics as the precursor laboratory thruster. The acceleration zone was found to move upstream with increasing background pressure, decreasing anode flowrate, and increasing magnetic field strength. For the low-energy ions, the energy of the ions arriving at the inner pole did not vary noticeably with background pressure but did increase with increasing magnetic field strength and decreasing anode flow rate. For the medium-energy ions, the energy of the ions increased with decreasing background pressure, decreasing anode flow rate, and increasing magnetic field strength. Testing at different cathode flow fraction showed that the energy of the low-energy ions from the cathode decreased with increasing cathode flow.

Electric propulsion↗
NASA NTRS1988

High variable mixture ratio oxygen/hydrogen engine

The ability of an O2/H2 engine to operate over a range of high-propellant mixture ratios was previously shown to be advantageous in single stage to orbit (SSTO) vehicles. The results are presented for the analysis of high-performance engine power cycles operating over propellant mixture ratio ranges of 12 to 6 and 9 to 6. A requirement to throttle up to 60 percent of nominal thrust was superimposed as a typical throttle range to limit vehicle acceleration as propellant is expended. The object of the analysis was to determine areas of concern relative to component and engine operability or potential hazards resulting from the operating requirements and ranges of conditions that derive from the overall engine requirements. The SSTO mission necessitates a high-performance, lightweight engine. Therefore, staged combustion power cycles employing either dual fuel-rich preburners or dual mixed (fuel-rich and oxygen-rich) preburners were examined. Engine mass flow and power balances were made and major component operating ranges were defined. Component size and arrangement were determined through engine layouts for one of the configurations evaluated. Each component is being examined to determine if there are areas of concern with respect to component efficiency, operability, reliability, or hazard. The effects of reducing the maximum chamber pressure were investigated for one of the cycles.

Erickson, C. M.↗