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At least 433 records · Page 24

PMR Graphite Engine Duct Development

The objective was to demonstrate the cost and weight advantages that could be obtained by utilizing the graphite/PMR15 material system to replace titanium in selected turbofan engine applications. The first component to be selected as a basis for evaluation was the outer bypass duct of the General Electric F404 engine. The operating environment of this duct was defined and then an extensive mechanical and physical property test program was conducted using material made by processing techniques which were also established by this program. Based on these properties, design concepts to fabricate a composite version of the duct were established and two complete ducts fabricated. One of these ducts was proof pressure tested and then run successfully on a factory test engine for over 1900 hours. The second duct was static tested to 210 percent design limit load without failure. An improved design was then developed which utilized integral composite end flanges. A complete duct was fabricated and successfully proof pressure tested. The net results of this effort showed that a composite version of the outer duct would be 14 percent lighter and 30 percent less expensive that the titanium duct. The other type of structure chosen for investigation was the F404 fan stator assembly, including the fan stator vanes. It was concluded that it was feasible to utilize composite materials for this type structure but that the requirements imposed by replacing an existing metal design resulted in an inefficient composite design. It was concluded that if composites were to be effectively used in this type structure, the design must be tailored for composite application from the outset.

Stotler, C. L.↗

Computation of turbulent incompressible wing-body junction flow

A three-dimensional incompressible Reynolds-averaged Navier-Stokes solver is presently used in conjunction with a mixing-length turbulence model to characterize the flow around a wing that is mounted on a flat plate, in a wind tunnel, as well as the flow around a support strut within a turnaround duct. Good agreement is found between predicted and observed values of flat-plate static pressure, horseshoe vortex system size, and mean flow velocities in the case of the wing; the case of the strut in a duct is noted to exhibit many of the same overall flow features as the wing/plate.

Burke, R. W.↗

FY23 Status Report on MOOSE-Based Approaches to Modeling Core Bowing in Fast Reactors

Under the U.S. Department of Energy Office of Nuclear Energy’s Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism whereby increased power (which leads to temperature and flux gradients) influences the core to bow into less reactive configurations when the restraint system is properly designed. The phenomenon includes a complex interplay of radiation transport, duct temperature calculations involving fluid flow and heat transfer, and thermo-mechanical responses to the induced temperature and flux gradients. Structural material properties are also important to determining inelastic response to longer term flux gradients which cause irradiation creep and swelling. While core bowing provides a strong negative reactivity feedback when the restraint system is designed properly, it also results in additional forces between assemblies which increase the loads required to extricate them during refueling or control rod movement. Therefore, the restraint system must be designed with these tradeoffs in mind. The first stage of the work, which commenced in FY21 and continues through FY23, assesses thermo-mechanical modeling tools for producing core bowing predictions consistent with conventional tools. The Multiphysics Object Oriented Simulation Environment (MOOSE) Tensor Mechanics and Contact Modules are employed. This status report describes work on additional thermo-mechanical benchmark verification problems with increased complexity from the examples demonstrated in FY21 and FY22. Several benchmark verification examples were selected from the IAEA verification and validation report with increased number of ducts and more complex contact interaction behavior. These examples involve a full symmetric sector with restraint rings at multiple load pad locations to simulate a limited free-bow restraint system concept, as well as irradiation induced swelling and creep effects in a sector. In addition, improvements to the contact module sideset assignment were assessed and compared with previous MOOSE results to verify the contact behavior. The MOOSE-based results were compared to IAEA benchmark participants’ results. In every case, the MOOSE results agreed with other simulations results for estimating bowing behavior, providing additional verification basis of the tools for this particular physics application. Estimation of contact forces were mostly in agreement, with a few outlier results. A plan was suggested for dealing with the discrepancies with estimating contact force values. In addition, a 1-way coupling demonstration was performed using subchannel analysis code Pronghorn-SC and MOOSE on an ABR-1000-design sodium-cooled fast reactor assembly to evaluate coolant and duct wall temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Composite load spectra for select space propulsion structural components

A multiyear program is performed with the objective to develop generic load models with multiple levels of progressive sophistication to simulate the composite (combined) load spectra that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades, and liquid oxygen (LOX) posts. Progress of the first year's effort includes completion of a sufficient portion of each task -- probabilistic models, code development, validation, and an initial operational code. This code has from its inception an expert system philosophy that could be added to throughout the program and in the future. The initial operational code is only applicable to turbine blade type loadings. The probabilistic model included in the operational code has fitting routines for loads that utilize a modified Discrete Probabilistic Distribution termed RASCAL, a barrier crossing method and a Monte Carlo method. An initial load model was developed by Battelle that is currently used for the slowly varying duty cycle type loading. The intent is to use the model and related codes essentially in the current form for all loads that are based on measured or calculated data that have followed a slowly varying profile.

Newell, J. F.↗

Investigation of Advanced Counterrotation Blade Configuration Concepts for High Speed Turboprop Systems. Task 3: Advanced Fan Section Grid Generator Final Report and Computer Program User's Manual

A procedure is studied for generating three-dimensional grids for advanced turbofan engine fan section geometries. The procedure constructs a discrete mesh about engine sections containing the fan stage, an arbitrary number of axisymmetric radial flow splitters, a booster stage, and a bifurcated core/bypass flow duct with guide vanes. The mesh is an h-type grid system, the points being distributed with a transfinite interpolation scheme with axial and radial spacing being user specified. Elliptic smoothing of the grid in the meridional plane is a post-process option. The grid generation scheme is consistent with aerodynamic analyses utilizing the average-passage equation system developed by Dr. John Adamczyk of NASA Lewis. This flow solution scheme requires a series of blade specific grids each having a common axisymmetric mesh, but varying in the circumferential direction according to the geometry of the specific blade row.

Crook, Andrew J.↗

VCE testbed program planning and definition study

The flight definition of the Variable Stream Control Engine (VSCE) was updated to reflect design improvements in the two key components: (1) the low emissions duct burner, and (2) the coannular exhaust nozzle. The testbed design was defined and plans for the overall program were formulated. The effect of these improvements was evaluated for performance, emissions, noise, weight, and length. For experimental large scale testing of the duct burner and coannular nozzle, a design definition of the VCE testbed configuration was made. This included selecting the core engine, determining instrumentation requirements, and selecting the test facilities, in addition to defining control system and assembly requirements. Plans for a comprehensive test program to demonstrate the duct burner and nozzle technologies were formulated. The plans include both aeroacoustic and emissions testing.

Westmoreland, J. S.↗

Progress with variable cycle engines

The evaluation of components of an advanced propulsion system for a future supersonic cruise vehicle is discussed. These components, a high performance duct burner for thrust augmentation and a low jet noise coannular exhaust nozzle, are part of the variable stream control engine. An experimental test program involving both isolated component and complete engine tests was conducted for the high performance, low emissions duct burner with excellent results. Nozzle model tests were completed which substantiate the inherent jet noise benefit associated with the unique velocity profile possible of a coannular exhaust nozzle system on a variable stream control engine. Additional nozzle model performance tests have established high thrust efficiency levels at takeoff and supersonic cruise for this nozzle system. Large scale testing of these two critical components is conducted using an F100 engine as the testbed for simulating the variable stream control engine.

Westmoreland, J. S.↗

Thermal Management System Modeling in the Heat Transport System Simulation (HeaTSSPy) Package

This paper describes the development of a thermal management system (TMS) concept design and analysis software package called Heat Transport System Simulation (HeaTSSPy). Built within Python using the OpenMDAO framework, HeaTSSPy can be used to size and optimize an active (using liquid/air heat exchangers) or passive (using finned heat sinks) TMS. The package makes use of modular TMS elements that allow for the creation of different system architectures and includes components such as heat sinks, heat exchangers, liquid pumps, fans, ducts, air inlets, air nozzles, and liquid pipes. Modeling methods for these components include a combination of physics-based analytical and empirical equations that relate component sizing criteria to system performance. The HeatSSPy heat sink methods are fully detailed within this paper, while the heat exchanger methods are described and referenced from previous work. This paper also uses high-fidelity simulation to validate two different methods of calculating thermal resistance using CFD results. Once the methods are fully described, the code is exercised to compare an active TMS with that of a passive TMS. Design criteria for this study include rejected heat, system altitude, Mach number, and ambient temperature. These criteria are used to develop a TMS system with estimated performance metrics such as weight, drag, and operational power. Results of this paper show the crossover point when a passive system begins to weigh more than an active system for a given heat rejection.

Thermal management system↗

Conceptual Design of Propulsors for the SUSAN Electrofan Transport Aircraft

Conceptual designs of the propulsor modules for the SUSAN electro-fan aircraft are sought after. Shaft power requirement is reduced by using boundary layer ingesting propulsion technology. There are several obstacles to designing feasible BLI propulsion systems such as inlet distortion, flow blockage from ingesting low-momentum flow, strong coupling between airframe and propulsion systems. Thus, the high fidelity CFD tool is indispensable to assess the performance of the propulsion systems and evaluate the inlet profiles during the design process. Consequently, the CFD data is used to update the inputs for the NPSS model from the initial stage of the system design. Hence, the inlet sizing, fan design, and estimation of the power saving are carried out. Various installation concepts of the mail-slot nacelle, such as under-/over-wing and trailing edge configurations, are investigated for the wing-mounted turbo-electric distributed propulsor module, and their power-saving is evaluated. As for the tail-mounted turbofan engine, the fan diameter and inlet captured area is determined based on the CFD profiles. An appropriate area ratio of the bypass and core ducts is derived from meeting the target bypass ratio from the system design. The baseline fan stage is analyzed by full annulus URANS CFD to assess the efficiency penalty due to the ingested pressure and swirl distortions.

SUSAN Electro-Fan Aircraft↗

Conceptual Design of Propulsors for the SUSAN Electrofan Transport Aircrafts

Conceptual designs of the propulsor modules for the SUSAN electro-fan aircraft are sought after. Shaft power requirement is reduced by using boundary layer ingesting propulsion technology. There are several obstacles to designing feasible BLI propulsion systems such as inlet distortion, flow blockage from ingesting low-momentum flow, strong coupling between airframe and propulsion systems. Thus, the high fidelity CFD tool is indispensable to assess the performance of the propulsion systems and evaluate the inlet profiles during the design process. Consequently, the CFD data is used to update the inputs for the NPSS model from the initial stage of the system design. Hence, the inlet sizing, fan design, and estimation of the power saving are carried out. Various installation concepts of the mail-slot nacelle, such as under-/over-wing and trailing edge configurations, are investigated for the wing-mounted turbo-electric distributed propulsor module, and their power-saving is evaluated. As for the tail-mounted turbofan engine, the fan diameter and inlet captured area is determined based on the CFD profiles. An appropriate area ratio of the bypass and core ducts is derived from meeting the target bypass ratio from the system design. The baseline fan stage is analyzed by full annulus URANS CFD to assess the efficiency penalty due to the ingested pressure and swirl distortions.

Electric Aircraft↗

Analysis of a New Rocket-Based Combined-Cycle Engine Concept at Low Speed

An analysis of the Independent Ramjet Stream (IRS) cycle is presented. The IRS cycle is a variation of the conventional ejector-Ramjet, and is used at low speed in a rocket-based combined-cycle (RBCC) propulsion system. In this new cycle, complete mixing between the rocket and ramjet streams is not required, and a single rocket chamber can be used without a long mixing duct. Furthermore, this concept allows flexibility in controlling the thermal choke process. The resulting propulsion system is intended to be simpler, more robust, and lighter than an ejector-ramjet. The performance characteristics of the IRS cycle are analyzed for a new single-stage-to-orbit (SSTO) launch vehicle concept, known as "Trailblazer." The study is based on a quasi-one-dimensional model of the rocket and air streams at speeds ranging from lift-off to Mach 3. The numerical formulation is described in detail. A performance comparison between the IRS and ejector-ramjet cycles is also presented.

Yungster, S.↗

Computational analysis of the flowfield of a two-dimensional ejector nozzle

A time-iterative full Navier-Stokes code, PARC, is used to analyze the flowfield of a two-dimensional ejector nozzle system. A parametric study was performed for two controlling parameters, duct to nozzle area ratio and nozzle pressure ratio. Results show that there is an optimum area ratio for the efficient pumping of secondary flow. At high area ratios, a freestream flow passes directly through the mixing duct without giving adequate pumping. At low area ratios, the jet boundary blocks the incoming flow. The nozzle pressure ratio variation shows that the pumping rate increases as the pressure ratio increases, provided there is no interaction between the shroud wall and the shock cell structure.

Choi, Y. H.↗

Computational analysis of the flowfield of a two-dimensional ejector nozzle

A time-iterative full Navier-Stokes code, PARC, is used to analyze the flowfield of a two-dimensional ejector nozzle system. A parametric study was performed for two controlling parameters, duct to nozzle area ratio and nozzle pressure ratio. Results show that there is an optimum area ratio for the efficient pumping of secondary flow. At high area ratios, a freestream flow passes directly through the mixing duct without giving adequate pumping. At low area ratios, the jet boundary blocks the incoming flow. The nozzle pressure ratio variation shows that the pumping rate increases as the pressure ratio increases, provided there is no interaction between the shroud wall and the shock cell structure.

Choi, Y. H.↗

Design and construction of a remote piloted flying wing

Currently, there is a need for a high-speed, high-lift civilian transport. Although unconventional, a flying wing could fly at speeds in excess of Mach 2 and still retain the capacity of a 747. The design of the flying wing is inherently unstable since it lacks a fuselage and a horizontal tail. The project goal was to design, construct, fly, and test a remote-piloted scale model flying wing. The project was completed as part of the NASA/USRA Advanced Aeronautics Design Program. These unique restrictions required us to implement several fundamental design changes from last year's Elang configuration including wing sweepback and wingtip endplates. Unique features such as a single ducted fan engine, composite structural materials, and an electrostatic stability system were incorporated. The result is the Banshee '94. Our efforts will aid future projects in design and construction techniques so that a viable flying wing can become an integral part of the aviation industry.

Costa, Alfred J.↗

Microsphere Insulation Panels

Microsphere insulation panels (MIPs) have been developed as lightweight, longlasting replacements for the foam and vacuum-jacketed systems heretofore used for thermally insulating cryogenic vessels and transfer ducts. The microsphere core material of a typical MIP consists of hollow glass bubbles, which have a combination of advantageous mechanical, chemical, and thermal-insulation properties heretofore available only separately in different materials. In particular, a core filling of glass microspheres has high crush strength and low density, is noncombustible, and performs well in soft vacuum.

Mohling, R.↗

A steam inerting system for hydrogen disposal for the Vandenberg Shuttle

A two-year feasibility and test program to solve the problem of unburned confined hydrogen at the Vandenberg Space Launch Complex Six (SLC-6) during Space Shuttle Main Engine (SSME) firings is discussed. A novel steam inerting design was selected for development. Available sound suppression water is superheated to flash to steam at the duct entrance. Testing, analysis, and design during 1987 showed that the steam inerting system (SIS) solves the problem and meets other flight-critical system requirements. The SIS design is complete and available for installation at SLC-6 to support shuttle or derivative vehicles.

Belknap, Stuart B.↗

Intelligent Integrated Health Management for a System of Systems

An intelligent integrated health management system (IIHMS) incorporates major improvements over prior such systems. The particular IIHMS is implemented for any system defined as a hierarchical distributed network of intelligent elements (HDNIE), comprising primarily: (1) an architecture (Figure 1), (2) intelligent elements, (3) a conceptual framework and taxonomy (Figure 2), and (4) and ontology that defines standards and protocols. Some definitions of terms are prerequisite to a further brief description of this innovation: A system-of-systems (SoS) is an engineering system that comprises multiple subsystems (e.g., a system of multiple possibly interacting flow subsystems that include pumps, valves, tanks, ducts, sensors, and the like); 'Intelligent' is used here in the sense of artificial intelligence. An intelligent element may be physical or virtual, it is network enabled, and it is able to manage data, information, and knowledge (DIaK) focused on determining its condition in the context of the entire SoS; As used here, 'health' signifies the functionality and/or structural integrity of an engineering system, subsystem, or process (leading to determination of the health of components); 'Process' can signify either a physical process in the usual sense of the word or an element into which functionally related sensors are grouped; 'Element' can signify a component (e.g., an actuator, a valve), a process, a controller, an actuator, a subsystem, or a system; The term Integrated System Health Management (ISHM) is used to describe a capability that focuses on determining the condition (health) of every element in a complex system (detect anomalies, diagnose causes, prognosis of future anomalies), and provide data, information, and knowledge (DIaK) not just data to control systems for safe and effective operation. A major novel aspect of the present development is the concept of intelligent integration. The purpose of intelligent integration, as defined and implemented in the present IIHMS, is to enable automated analysis of physical phenomena in imitation of human reasoning, including the use of qualitative methods. Intelligent integration is said to occur in a system in which all elements are intelligent and can acquire, maintain, and share knowledge and information. In the HDNIE of the present IIHMS, an SoS is represented as being operationally organized in a hierarchical-distributed format. The elements of the SoS are considered to be intelligent in that they determine their own conditions within an integrated scheme that involves consideration of data, information, knowledge bases, and methods that reside in all elements of the system. The conceptual framework of the HDNIE and the methodologies of implementing it enable the flow of information and knowledge among the elements so as to make possible the determination of the condition of each element. The necessary information and knowledge is made available to each affected element at the desired time, satisfying a need to prevent information overload while providing context-sensitive information at the proper level of detail. Provision of high-quality data is a central goal in designing this or any IIHMS. In pursuit of this goal, functionally related sensors are logically assigned to groups denoted processes. An aggregate of processes is considered to form a system. Alternatively or in addition to what has been said thus far, the HDNIE of this IIHMS can be regarded as consisting of a framework containing object models that encapsulate all elements of the system, their individual and relational knowledge bases, generic methods and procedures based on models of the applicable physics, and communication processes (Figure 2). The framework enables implementation of a paradigm inspired by how expert operators monitor the health of systems with the help of (1) DIaK from various sources, (2) software tools that assist in rapid visualization of the condition of the system, (3) analical software tools that assist in reasoning about the condition, (4) sharing of information via network communication hardware and software, and (5) software tools that aid in making decisions to remedy unacceptable conditions or improve performance.

Smith, Harvey↗