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At least 433 records · Page 24

All sources NASA NTRS DOE OSTI

NASA NTRS1994

Quality optimization of thermally sprayed coatings produced by the JP-5000 (HVOF) gun using mathematical modeling

Currently, thermal barrier coatings (TBC) of gas-turbine blades and similar applications have centered around the use of zirconia as a protective coating for high thermal applications. The advantages of zirconia include low thermal conductivity and good thermal shock resistance. Thermally sprayed tungsten carbide hardface coatings are used for a wide range of applications spanning both the aerospace and other industrial markets. Major aircraft engine manufacturers and repair facilities use hardface coatings for original engine manufacture (OEM), as well as in the overhaul of critical engine components. The principle function of these coatings is to resist severe wear environments for such wear mechanisms as abrasion, adhesion, fretting, and erosion. The (JP-5000) thermal spray gun is the most advanced in the High Velocity Oxygen Fuel (HVOF) systems. Recently, it has received considerable attention because of its relative low cost and its production of quality coatings that challenge the very successful but yet very expensive Vacuum Plasma Spraying (VPS) system. The quality of thermal spray coatings is enhanced as porosity, oxidation, residual stress, and surface roughness are reduced or minimized. Higher densification, interfacial bonding strength, hardness and wear resistance of coating are desirable features for quality improvement.

Tawfik, Hazem↗

DOE OSTI2021

Preheating and premixing effects on NO x emissions in a high-pressure axially staged combustor

NO x emissions remain a primary concern for modern and future gas turbines, particularly as we progress towards a net-zero carbon future. It is critical to identify novel strategies to mitigate environmental pollutants for both modern turbines operated on natural gas and future turbines projected to use carbon-free fuels (such as hydrogen). In the current study, NO x emissions of a reacting methane-air jet in a vitiated crossflow are experimentally investigated in a model axially staged combustor at 5 atm. The combustion products from the main stage combustor flow into the axial stage at temperatures ranging from 1580 to 1650 °C. The axial stage contains a reacting jet in crossflow, which provides an overall temperature rise ranging from 50 to 220 °C to generate exit temperatures similar to gas turbine engines. The focus of this paper is to explore the effects of flame liftoff and ignition timescales on the NO x contribution of this secondary jet. This is done by varying the premixed level and preheat temperature of the axial jet. The effects are explored at different momentum flux ratios (J), jet equivalence ratios (φ jet ), exit temperatures (T exit ), and main stage (headend) temperatures (T HE ). High-speed CH* chemiluminescence imaging is employed for each test case to determine the flame stabilization point. For a given temperature rise and combustor exit temperature, an increase in ignition delay was observed with a decrease in jet temperature. This provided a NO x benefit, particularly for jets that are injected at or close to an ignitable mixture fraction. Similarly, the coaxial injector caused a significant ignition delay compared to the fully premixed injector; this also led to a NO x benefit. Overall, the results show that a thermally driven delay in the axial stage provides a greater NO x reduction than a mixing delay.

03 NATURAL GAS↗

NASA NTRS1990

Heat transfer in rotating serpentine passages with smooth walls

Experiments were conducted to determine the effects of buoyancy and Coriolis forces on heat transfer in turbine blade internal coolant passages. The experiments were conducted with a large scale, multi-pass, smooth-wall heat transfer model with both radially inward and outward flow. An analysis of the governing flow equations showed that four parameters influence the heat transfer in rotating passages (coolant-to-wall temperature ratio, Rossby number, Reynolds number and radius-to-passage hydraulic diameter ratio). These four parameters were varied over ranges which are typical of advanced gas turbine engine operating conditions. It was found that both Coriolis and buoyancy effects must be considered in turbine blade cooling designs and that the effect of rotation on the heat transfer coefficients was markedly different depending on the flow direction. Local heat transfer coefficients were found to decrease by as much as 60 percent and increase by 250 percent from no rotation levels. Comparisons with a pioneering stationary vertical tube buoyancy experiment showed reasonably good agreement. Correlation of the data is achieved employing dimensionless parameters derived from the governing flow equations.

Wagner, J. H.↗

NASA NTRS1988

Review and assessment of the HOST turbine heat transfer program

The objectives of the HOST Turbine Heat Transfer subproject were to obtain a better understanding of the physics of the aerothermodynamic phenomena occurring in high-performance gas turbine engines and to assess and improve the analytical methods used to predict the fluid dynamics and heat transfer phenomena. At the time the HOST project was initiated, an across-the-board improvement in turbine design technology was needed. Therefore, a building-block approach was utilized, with research ranging from the study of fundamental phenomena and analytical modeling to experiments in simulated real-engine environments. Experimental research accounted for 75 percent of the project, and analytical efforts accounted for approximately 25 percent. Extensive experimental datasets were created depicting the three-dimensional flow field, high free-stream turbulence, boundary-layer transition, blade tip region heat transfer, film cooling effects in a simulated engine environment, rough-wall cooling enhancement in a rotating passage, and rotor-stator interaction effects. In addition, analytical modeling of these phenomena was initiated using boundary-layer assumptions as well as Navier-Stokes solutions.

Gladden, Herbert J.↗

DOE OSTI2022

Use of Multiple Tracer Gases to Quantify Vane Trailing Edge Flow Into Turbine Rim Seals

Abstract Overlapping features are commonly used as rim seals between stationary and rotating components in a turbine stage. These rim seals are used to prevent main gas path ingestion to the wheelspace cavity, which reduces the lifespan of critical engine components such as the turbine disk. In addition to the overlapping features, purge flow, diverted from the compressor, is injected into the rim cavity to act as an airflow sealing mechanism. Previous research identified that in addition to the purge flow in the rim cavity, cooling flow from the vane trailing edge (VTE) is ingested into the rim seal cavity carrying the potential to cool components in the wheelspace. These previous findings, however, were not able to distinctly separate purge from VTE cooling flows, which is the contribution of this paper based on uniquely using two different tracer gases. A one-stage test turbine operating at engine-relevant conditions and consisting of real engine hardware was used to validate and quantify the ingestion of the VTE flow by independently seeding the purge and VTE flows with two different tracer gases. Experimental results show the presence of VTE flow in the rim seal throughout all purge flowrates evaluated. Circumferential variation of VTE flow was also studied both experimentally and computationally using a computational fluid dynamics model. Results showed that ingested VTE flow can reduce the detrimental effect of hot gas ingestion particularly at higher purge flowrates.

Engineering↗

DOE OSTI2021

Advanced Multi-Tube Mixer Combustion for 65% Efficiency (Final Report)

This project targeted advanced low NOx combustion for advanced gas turbines capable of 65%, or greater, efficiency in combined cycle application. This technology advancement has further potential to benefit gas turbines used in coal based IGCC applications with pre-combustion carbon capture and hydrogen as the resulting fuel. The program developed and synthesized the most advanced combustion system capable of achieving low NOX emissions up to turbine inlet temperatures of 3100F while also supporting the load-following needs of a modern grid. The combustion system contributes to the overall gas turbine efficiency goal by setting the maximum cycle temperature achievable for a given NOX level and by minimizing the through-combustor air flow pressure drop. Focus areas for this project targeted maximizing the turbine inlet temperature entitlement, as constrained by emissions considerations. The design also minimized parasitic air flow pressure drop by using advanced cooling techniques and performance materials selections and by minimizing hot surface area. These two technology objectives (maximum, emissions-compliant cycle temperature and minimum air flow pressure drop) were integrated into a prototype design. The primarily analytical project sought to identify the most promising technologies to meet these objectives. Additional critical “jugular” data were obtained from multi-tube mixer tests to realize the potential of leveraging “micro flames” for minimizing overall hot surface area. This data was used, in conjunction with an understanding of advanced material and cooling design technologies, to analytically develop multiple design concepts. Phase I focused on in-depth engineering analysis and design, with minimal supporting laboratory testing to enable a selection of the top three combustion architectures for achieving these overall objectives. Phase II of the program developed the selected design through a combination of sub-scale testing and analytical efforts. Early tests included a cold-flow cascade to establish aerodynamic performance characteristics and a sub-scale fired test at GE Global Research in Niskayuna, NY, to establish cooling and heat transfer characteristics in conjunction with combustion performance. The data from these tests validated the analytical models to ultimately design a full-scale, test article to evaluate at prototypical pressure and temperature conditions at GE Gas Power’s Gas Turbine Technology Laboratory in Greenville, SC. GE Gas Power also developed, tested, and recommended a suitable seal design to be applied to the unique features of the combustor. To assess the technology challenges from prospective future production of the combustor from a ceramic matrix composite material, screening tests of Environmental Barrier Coatings were completed.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1995

Thermal barrier coating experience in the gas turbine engine

Thermal Barrier Coatings (TBC), provide thermal insulation and oxidation resistance in an environment consisting of hot combustion gases. TBC's consist of a two layer system. The outer ceramic layer provides good thermal insulation due to the low thermal conductivity of the ceramic coatings used, while the inner metallic bond coat layer provides needed oxidation resistance to the underlying superalloy. Pratt & Whitney has over a decade of experience with several generations of TBC systems on turbine airfoils. This paper will focus on the latest TBC field experience along with a proposed durability model.

Bose, S.↗

NASA NTRS2015

Thermochemistry of Silicates

The thermodynamic properties of vapor and condensed phases of silicates are crucial in many fields of science. These quantities address fundamental questions on the formation, stability, transformation, and physical properties of silicate minerals and silicate coating compositions. Here the thermodynamic activities of silica and other species in solid solution have been measured by the analysis of the corresponding high temperature vapors using Knudsen Effusion Mass Spectrometry (KEMS). In first set of experiments KEMS has been used to examine the volatility sequence of species (Fe, SiO, Mg, O2 and O) present in the vapor phase during heating of fosterite-rich olivine (Fo93Fa7) up to 2400 C and to measure the Fe, SiO and Mg activities in its solid solution. The data of fosterite-rich olivine are essential for thermochemical equilibrium models to predict the atmospheric and surface composition of hot, rocky exoplanets (Lava Planets). In the second set of experiments the measured thermodynamic activities of the silica in Y2O3-SiO2 and Yb2O3-SiO2 systems are used to assess their reactivity and degradation recession as environmental barrier coatings (EBCs) in combustion environments (e.g. non-moveable parts of gas turbine engine).

Silicates↗

NASA NTRS2002

Minnowbrook III: 2000 Workshop on Boundary Layer Transition and Unsteady Aspects of Turbomachinery Flows

This volume and its accompanying CD-ROM contain materials presented at the Minnowbrook III-2000 Workshop on Boundary Layer Transition and Unsteady Aspects of Turbomachinery Flows held at the Syracuse University Minnowbrook Conference Center, Blue Mountain Lake, New York, August 20-23, 2000. Workshop organizers were John E. LaGraff (Syracuse University), Terry V Jones (Oxford University), and J. Paul Gostelow (University of Leicester). The workshop followed the theme, venue, and informal format of two earlier workshops: Minnowbrook I (1993) and Minnowbrook II (1997). The workshop was focused on physical understanding the late stage (final breakdown) boundary layer transition, separation, and effects of unsteady wakes with the specific goal of contributing to engineering application of improving design codes for turbomachinery. The workshop participants included academic researchers from the USA and abroad, and representatives from the gas-turbine industry and government laboratories. The physical mechanisms discussed included turbulence disturbance environment in turbomachinery, flow instabilities, bypass and natural transition, turbulent spots and calmed regions, wake interactions with attached and separated boundary layers, turbulence and transition modeling and CFD, and DNS. This volume contains abstracts and copies of the viewgraphs presented, organized according to the workshop sessions. The viewgraphs are included on the CD-ROM only. The workshop summary and the plenary-discussion transcripts clearly highlight the need for continued vigorous research in the technologically important area of transition, separated and unsteady flows in turbomachines.

LaGraff, John E.↗

NASA NTRS2000

Global Design Optimization for Aerodynamics and Rocket Propulsion Components

Modern computational and experimental tools for aerodynamics and propulsion applications have matured to a stage where they can provide substantial insight into engineering processes involving fluid flows, and can be fruitfully utilized to help improve the design of practical devices. In particular, rapid and continuous development in aerospace engineering demands that new design concepts be regularly proposed to meet goals for increased performance, robustness and safety while concurrently decreasing cost. To date, the majority of the effort in design optimization of fluid dynamics has relied on gradient-based search algorithms. Global optimization methods can utilize the information collected from various sources and by different tools. These methods offer multi-criterion optimization, handle the existence of multiple design points and trade-offs via insight into the entire design space, can easily perform tasks in parallel, and are often effective in filtering the noise intrinsic to numerical and experimental data. However, a successful application of the global optimization method needs to address issues related to data requirements with an increase in the number of design variables, and methods for predicting the model performance. In this article, we review recent progress made in establishing suitable global optimization techniques employing neural network and polynomial-based response surface methodologies. Issues addressed include techniques for construction of the response surface, design of experiment techniques for supplying information in an economical manner, optimization procedures and multi-level techniques, and assessment of relative performance between polynomials and neural networks. Examples drawn from wing aerodynamics, turbulent diffuser flows, gas-gas injectors, and supersonic turbines are employed to help demonstrate the issues involved in an engineering design context. Both the usefulness of the existing knowledge to aid current design practices and the need for future research are identified.

Shyy, Wei↗

DOE OSTI2023

Cost and Performance Baseline for Fossil Energy Plants, Volume 5: Natural Gas Electricity Generating Units for Flexible Operation

To address the data needs of energy system designers and to serve as a baseline for research and development, NETL has carried out a study to characterize the flexibility attributes - both performance and cost - of nine common commercial natural gas-fueled electricity generating units. The intermittent output of low-carbon, renewable power generation sources such as wind and solar create challenges to grid stability and reliability. Fossil-fueled power generation technologies are currently used to provide reliable, on-demand power during periods of reduced renewable output. Dispatchable generators must be able to accommodate increasing renewable generation as the nation pursues the Administration’s target of a decarbonized energy sector by 2035. As energy system experts seek to identify least-cost approaches to decarbonization, accurate cost and performance data characterizing dispatchable fossil generators that operate flexibly, at capacity factors that have been declining over time, and are needed to inform models for capacity expansion. Furthermore, these technologies continue to be a significant source of carbon dioxide emissions, providing the impetus for research and development, including the advancement and potential incorporation of carbon capture technologies. This study characterizes the cost and performance of select state-of-the-art natural gas-fueled power generation technologies: reciprocating internal combustion engines (RICE), simple cycle combustion turbines, and natural gas combined cycles (NGCC). An emphasis is placed on flexibility characteristics, such as part-load heat rate, ramp rates, start up times, and start up costs.

03 NATURAL GAS↗

NASA NTRS1986

Combustion research in the Internal Fluid Mechanics Division

The goal of this research is to bring computational fluid dynamics to a state of practical application for the aircraft engine industry. The approach is to have a strongly integrated computational and experimental program for all the disciplines associated with the gas turbine and other aeropropulsion systems by advancing the understanding of flow physics, heat transfer, and combustion processes. The computational and experimental research is integrated in the following way: the experiments that are performed provide an empirical data set so that physical models can be formulated to describe the processes that are occurring - for example, turbulence or chemical reaction. These experiments also form a data base for those who are doing code development by providing experimental data against which the codes can be verified and assesed. Models are generated as closure to some of the numerical codes, and they also provide physical insight for experiments. At the same time, codes which solve the complete Navier-Stokes equations can be used as a kind of numerical experiment from which far more extensive data can be obtained than ever could be obtained experimentally. This could provide physical insight into the complex processes that are taking place. These codes are also exercised against experimental data to assess the accuracy and applicability of models.

Mularz, Edward J.↗

NASA NTRS2011

Optimal Tuner Selection for Kalman-Filter-Based Aircraft Engine Performance Estimation

An emerging approach in the field of aircraft engine controls and system health management is the inclusion of real-time, onboard models for the inflight estimation of engine performance variations. This technology, typically based on Kalman-filter concepts, enables the estimation of unmeasured engine performance parameters that can be directly utilized by controls, prognostics, and health-management applications. A challenge that complicates this practice is the fact that an aircraft engine s performance is affected by its level of degradation, generally described in terms of unmeasurable health parameters such as efficiencies and flow capacities related to each major engine module. Through Kalman-filter-based estimation techniques, the level of engine performance degradation can be estimated, given that there are at least as many sensors as health parameters to be estimated. However, in an aircraft engine, the number of sensors available is typically less than the number of health parameters, presenting an under-determined estimation problem. A common approach to address this shortcoming is to estimate a subset of the health parameters, referred to as model tuning parameters. The problem/objective is to optimally select the model tuning parameters to minimize Kalman-filterbased estimation error. A tuner selection technique has been developed that specifically addresses the under-determined estimation problem, where there are more unknown parameters than available sensor measurements. A systematic approach is applied to produce a model tuning parameter vector of appropriate dimension to enable estimation by a Kalman filter, while minimizing the estimation error in the parameters of interest. Tuning parameter selection is performed using a multi-variable iterative search routine that seeks to minimize the theoretical mean-squared estimation error of the Kalman filter. This approach can significantly reduce the error in onboard aircraft engine parameter estimation applications such as model-based diagnostic, controls, and life usage calculations. The advantage of the innovation is the significant reduction in estimation errors that it can provide relative to the conventional approach of selecting a subset of health parameters to serve as the model tuning parameter vector. Because this technique needs only to be performed during the system design process, it places no additional computation burden on the onboard Kalman filter implementation. The technique has been developed for aircraft engine onboard estimation applications, as this application typically presents an under-determined estimation problem. However, this generic technique could be applied to other industries using gas turbine engine technology.

Simon, Donald L.↗

NASA NTRS1985

Turbine airfoil deposition models and their hot corrosion implications

This research project deals with the prediction of single- and multi-component salt(-solution) deposition, flow and oxide dissolution and their effects on the lifetime of turbine blades. Goals include rationalizing and helping to predict corrosion patterns on operational gas turbine (GT) rotor blades and stator vanes, and ultimately providing some of the tools required to design laboratory simulators and future corrosion resistant high-performance engines. Necessary background developments are reviewed. Results and tentative conclusions for single species (Na sub 2 SO sub 4 (1)) condensation, binary salt-solution (Na sub 2 SO sub 4-K sub 2 SO sub 4) condensation, and burner-rig testing of alloy materials are outlined.

Rosner, D. E.↗

NASA NTRS2007

Transition Models for Engineering Calculations

While future theoretical and conceptual developments may promote a better understanding of the physical processes involved in the latter stages of boundary layer transition, the designers of rotodynamic machinery and other fluid dynamic devices need effective transition models now. This presentation will therefore center around the development of of some transition models which have been developed as design aids to improve the prediction codes used in the performance evaluation of gas turbine blading. All models are based on Narasimba's concentrated breakdown and spot growth.

Fraser, C. J.↗

DOE OSTI2026

Mechanism, Thermochemistry, and Kinetics for the CH + N 2 Reaction Leading to Prompt NO Formation in Combustion

Here, the reaction of CH + N 2 forming H + NCN is a remarkable example of activation of the nitrogen triple bond and is an important source of prompt NO in combustion. The reaction pathway is complex and proceeds through two competing mechanisms: a cyclic addition channel initiated by c-HC(NN) and a chain-addition channel initiated by HCNN, both of which eventually form HNCN prior to dissociation to H + NCN. This work reinvestigates this reaction with composite coupled cluster protocols, including a novel spin-flip equation of motion coupled cluster scheme, combined with pragmatic two-dimensional master equation simulations of the resulting rate coefficients. These improved calculations predict the CH + N 2 rate coefficient between the two more recent previous theoretical results and reduce the uncertainties of the best theoretical models of this reaction to less than a factor of 1.3. Additionally, we provide a closer theoretical investigation of the simultaneous dependence of the CH + N 2 rate coefficient on pressure and temperature, and affirm that collisionally stabilized HNCN, another potential source of prompt NO, emerges as an appreciable product of this reaction under conditions relevant to automotive internal combustion engines and aircraft gas turbine engines.

Nguyen, Thanh Lam [Univ. of Florida, Gainesville, ↗

NASA NTRS1983

An experimental investigation of endwall heat transfer and aerodynamics in a linear vane cascade

The purpose of this experimental investigation was to produce a data base of endwall heat transfer data under conditions that simulate those in the passage of the first-stage stator in advanced turbine engines. The data base is intended to be sufficiently complete to provide verification data for refined computational models, and to provide a basis for advanced core engine endwall cooling designs. A linear, two-dimensional cascade was used to generate the data base. The test plan provided data to examine the effects of exit Mach number, exit Reynolds number, inlet boundary layer thickness, gas-to-wall temperature ratio, inlet pressure gradients, and inlet temperature gradients. The data generated consist of inlet, intrapassage, and exit aerodynamic data plus intrapassage endwall heat flux, adiabatic wall temperature measurements, and inlet turbulence data.

York, R. E.↗

NASA NTRS1988

NNEPEQ: Chemical equilibrium version of the Navy/NASA Engine Program

The Navy NASA Engine Program, NNEP, currently is in use at a large number of government agencies, commercial companies and universities. This computer code has bee used extensively to calculate the design and off-design (matched) performance of a broad range of turbine engines, ranging from subsonic turboprops to variable cycle engines for supersonic transports. Recently, there has been increased interest in applications for which NNEP was not capable of simulating, namely, high Mach applications, alternate fuels including cryogenics, and cycles such as the gas generator air-turbo-rocker (ATR). In addition, there is interest in cycles employing ejectors such as for military fighters. New engine component models had to be created for incorporation into NNEP, and it was found necessary to include chemical dissociation effects of high temperature gases. The incorporation of these extended capabilities into NNEP is discussed and some of the effects of these changes are illustrated.

Fishbach, Laurence H.↗