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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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548 records · Page 31
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

CFD Simulation of an Inward-Turning Supersonic Inlet Unstart at Flight Mach Number 1.7

Interest in inward-turning supersonic inlets renewed during NASA’s Commercial Supersonic Technology Project, as a means of reducing disturbances caused by propulsion integration. Inward-turning designs have the potential to greatly reduce the strength of shock waves emanating outward from the nacelle, and therefore their contribution to the overall sonic boom signature. For top-mounted, or over-wing installations, disturbances to aircraft aerodynamics are reduced. The nature of the inward-turning geometry results in a boundary-layer thickening effect, opposite that of the familiar thinning of an outward-turning cone boundary-layer. The application of a small amount of boundary-layer bleed at the throat has been shown to alleviate the negative effects of the boundary-layer on subsonic diffuser performance. Boundary-layer bleed, however, comes at the expense of increased complexity, and external disturbances at bleed exits that would partially defeat the purpose of the inward-turning scheme. Vortex generators were proposed as an alternative to bleed, and an initial CFD study of their effectiveness in this application forms the basis of the present work. A source-term model in the Wind-US CFD code was used to model the effects of an array of vortex generators placed at the entrance to the subsonic diffuser. Baseline results with no vortex generators compared favorably to previously reported results with no bleed at back-pressures near the design point, but stability margin in the present case was limited by a curious non-linear phenomena similar to unstart in mixed-compression inlets. While some improvement was noted with vortex generators, their effectiveness was diminished by the limited stability margin. A time-accurate calculation was subsequently performed to better understand this process. Results of this calculation are presented and instantaneous solutions compared with steady-state, subcritical results previously reported. The stability margin limitation is attributed to the use of a constant-pressure outflow boundary condition, which differed from that used in the prior simulations.

Pre-Compressor Cooling, Water Injection, Hypersoni↗
NASA NTRSDate not supplied

Vision 2030 Aircraft Propulsion Grand Challenge Problem: Full-engine CFD Simulations with High Geometric Fidelity and Physics Accuracy

In 2014 NASA published the outcome of the 2030 CFD Vision study: “CFD Vision 2030: A path to Revolutionary Computational Aerosciences” (Slotnick et al., 2014). The study provided a comprehensive review of the state of the art of CFD in 2014 for aerospace applications including, but not limited to, numerical algorithms, physics models, MDAO and HPC hardware. The study also proposed four conceptual ideas of Grand Challenge problems that would benefit from advances outlined in the roadmap including “off-design turbofan engine transient simulation”. The proposed challenges served as a starting point for more detailed problem descriptions that would benefit from advances in simulation. The objective of this paper is to build upon the NASA 2030 CFD Vision study and provide a detailed overview of what needs to take place to enable accurate and efficient simulation of flow through an aircraft engine at off-design condition for transient operation . Execution of the proposed roadmap would significantly advance aircraft engine development by reducing program cost, reducing program development timelines and enabling design objectives associated with Specific Fuel Consumption (SFC), noise, weight and durability.

compressor↗
NASA NTRS1992

Navier-Stokes analysis and experimental data comparison of compressible flow within ducts

Many aircraft employ ducts with centerline curvature or changing cross-sectional shape to join the engine with inlet and exhaust components. S-ducts convey air to the engine compressor from the intake and often decelerate the flow to achieve an acceptable Mach number at the engine compressor by increasing the cross-sectional area downstream. Circular-to-rectangular transition ducts are used on aircraft with rectangular exhaust nozzles to connect the engine and nozzle. To achieve maximum engine performance, the ducts should minimize flow total pressure loss and total pressure distortion at the duct exit. Changes in the curvature of the duct centerline or the duct cross-sectional shape give rise to streamline curvature which causes cross stream pressure gradients. Secondary flows can be caused by deflection of the transverse vorticity component of the boundary layer. This vortex tilting results in counter-rotating vortices. Additionally, the adverse streamwise pressure gradient caused by increasing cross-sectional area can lead to flow separation. Vortex pairs have been observed in the exit planes of both duct types. These vortices are due to secondary flows induced by pressure gradients resulting from streamline curvature. Regions of low total pressure are produced when the vortices convect boundary layer fluid into the main flow. The purpose of the present study is to predict the measured flow field in a diffusing S-duct and a circular-to-rectangular transition duct with a full Navier-Stokes computer program, PARC3D, and to compare the numerical predictions with new detailed experimental measurements. The work was undertaken to extend previous studies and to provide additional CFD validation data needed to help model flows with strong secondary flow and boundary layer separation. The S-duct computation extends the study of Smith et al, and Harloff et al, which concluded that the computation might be improved by using a finer grid and more advanced turbulence models. The present study compares results for both the Baldwin-Lomas and k-epsilon turbulence models and is conducted with a refined grid. For the transition duct, two inlet conditions were considered, the first with straight flow and the second with swirling flow. The first case permits examination of the effects of the geometric transition on the flow field, while the second case includes the rotational flow effect characteristic of a gas turbine engine.

Harloff, G. J.↗
NASA NTRS1957

Preliminary Wind-Tunnel Investigation of the Performance of Republic F-105 Wing-Root Inlet Configurations at Various Angles of Attack and a Mach Number of 2.01

A 1/13-scale model of the forebody of the Republic F-105 with twin-duct wing-root inlets was tested in the Langley 4- by 4-foot supersonic pressure tunnel through a range of angle of attack from -4 deg to 15 deg at a Mach number of 2.01 and a Reynolds number of approximately 3.4 x 10(exp 6) per foot. The tests were made with four configurations which incorporated varying amounts of sweep and stagger of the inlet leading edges, modifications to the areas of the boundary-layer diverter floor plate, and modifications to the area of the boundary-layer diverter bleed slots. The highest overall pressure recovery at an angle of attack of 0 deg (average total-pressure recovery, 0.84 mass-flow ratio, 0.98) was achieved with configuration having an inlet leading-edge sweep angle of 58 deg with no leading-edge stagger. Stagger was found to improve the angle-of- attack performance, but at a sacrifice in inlet efficiency for an angle of attack of 0 deg. The boundary-layer diverter floor height, of the order of one boundary-layer thickness, was satisfactory for bypassing the fuselage boundary layer. The boundary-layer diverter-plate bleed slots were effective in increasing the total-pressure recovery of the inlet. The total-pressure-recovery contour plots, taken at the compressor-face station, indicate the existence of high-velocity "cores" throughout the inlet operating range.

Kouyoumjian, W. L.↗
NASA NTRSDate not supplied

Ice Crystal Icing Investigation on a Honeywell Uncertified Research Engine in an Altitude Simulation Icing Facility

A Honeywell Uncertified Research Engine was exposed to various ice crystal conditions in the NASA Glenn Propulsion Systems Laboratory. Simulations using NASA's 1D Icing Risk Analysis tool were used to determine potential inlet conditions that could lead to ice crystal accretion along the inlet of the core flowpath and into the high pressure compressor. These conditions were simulated in the facility to develop baseline conditions. Parameters were then varied to move or change accretion characteristics. Data were acquired at altitudes varying from 5 kft to 45 kft, at nominal ice particle Median Volumetric Diameters from 20 µm to 100 µm, and total water contents of 1 g/m3 to 12 g/m3. Engine and flight parameters such as fan speed, Mach number, and inlet temperature were also varied. The engine was instrumented with total temperature and pressure probes. Static pressure taps were installed at the leading edge of the fan stator, front frame hub, the shroud of the IGV, and first two rotors. Metal temperatures were acquired for vane stators 1-2. In-situ measurements of the particle size distribution were acquired three meters upstream of the engine forward fan flange and one meter downstream of the fan in the bypass in order to study particle break-up behavior. Cameras were installed in the engine to capture ice accretions at the leading edge of the fan stator, splitter lip, and inlet guide vane. Additional measurements acquired but not discussed in this paper include: high speed pressure transducers installed at the trailing edge of the first stage rotor and light extinction probes used to acquire particle concentrations at the fan exit stator plane and at the inlet to the core and bypass. The goal of this study was to understand key parameters of accretion, acquire particle break-up data aft of the fan, and generate a unique icing dataset for model and tool development. This work described in the paper focuses on the effect of particle break-up. It was found that there was significant particle break-up downstream of the fan in the bypass especially with larger initial particle sizes. The metal temperatures on the inlet guide vanes and stators show a temperature increase with increasing MVD. Accretion behavior was very similar across all test cases. However at the inlet guide vanes, the accretion decreased with increasing particle size.

Ashlie B Flegel↗
NASA NTRS1995

The effect of adding roughness and thickness to a transonic axial compressor rotor

The performance deterioration of a high speed axial compressor rotor due to surface roughness and airfoil thickness variations is reported. A 0.025 mm (0.001 in.) thick rough coating with a surface finish of 2.54-3.18 RMS microns (100-125 RMS microinches) is applied to the pressure and suction surface of the rotor blades. Coating both surfaces increases the leading edge thickness by 10% at the hub and 20% at the tip. Application of this coating results in a loss in efficiency of 6 points and a 9% reduction in the pressure ratio across the rotor at an operating condition near the design point. To separate the effect of thickness and roughness, a smooth coating of equal thickness is also applied to the blade. The smooth coating surface finish is 0.254-0.508 RMS microns (10-20 RMS microinches), compared to the bare metal blade surface finish of 0.508 RMS microns (20 RMS microinches). The smooth coating results in approximately half of the performance deterioration found from the rough coating. Both coatings are then applied to different portions of the blade surface to determine which portions of the airfoil are most sensitive to thickness/roughness variations. Aerodynamic performance measurements are presented for a number of coating configurations at 60%, 80%, and 100% of design speed. The results indicate that thickness/roughness over the first 10% of blade chord accounts for virtually all of the observed performance degradation for the smooth coating, compared to about 70% of the observed performance degradation for the rough coating. The performance deterioration is investigated in more detail at design speed using laser anemometer measurements as well as predictions generated by a quasi-3D Navier-Stokes flow solver which includes a surface roughness model. Measurements and analysis are performed on the baseline blade and the full-coverage smooth and rough coatings. The results indicate that coating the blade causes a thickening of the blade boundary layers. The interaction between the rotor passage shock and the thickened suction surface boundary layer then results in an increase in blockage which reduces the diffusion level in the rear half of the blade passage, thus reducing the aerodynamic performance of the rotor.

Suder, Kenneth L.↗
NASA NTRS1998

Effects of regenerator geometry on pulse tube refrigerator performance

This paper gives results of the cooling performance of a double-inlet pulse tube refrigerator using various regenerators. The same pulse tube was used for all the experiments and measured 4.76 mm in diameter and 46.2 mm in length. A commercial linear compressor with a swept volume of 4 cm3 was used in these experiments. The operating conditions were held constant at a mean pressure of 2.0 MPa and a frequency of 54 Hz. Using finite difference software called REGEN3.1, developed at NIST, and recent experiment results, we optimized a series of regenerators based on dimensions, materials and screen packing. The values used for calculating the thermal conduction through stacked screens by REGEN3.1 were based on recent experimental results from NIST. The regenerator tubes were designed using 316 stainless steel and titanium materials. The regenerator matrices investigated were 400-mesh and 500-mesh stainless steel screen. The valve settings for both orifices were adjusted to minimize the no-load temperature for all regenerators. A cooling capacity curve from 0 to 3 W was also determined. The performance of the pulse tube refrigerator using the different regenerators is discussed. The experimental results from the various regenerators are evaluated and compared with their corresponding numerically calculated coefficient of performance (COP) and regenerator design as determined by REGEN3.1.

NASA Discipline Life Sciences Technologies↗
NASA NTRS2002

Major Effects of Nonmetallic Inclusions on the Fatigue Life of Disk Superalloy Demonstrated

The fatigue properties of modern powder metallurgy disk alloys can vary because of the different steps of materials and component processing and machining. Among these variables, the effects of nonmetallic inclusions introduced during the powder atomization and handling processes have been shown to significantly degrade low-cycle fatigue life. The levels of inclusion contamination have, therefore, been reduced to less than 1 part per million in state-of-the-art nickel disk powder-processing facilities. Yet the large quantities of compressor and turbine disks weighing from 100 to over 1000 lb have enough total volume and surface area for these rare inclusions to still be present and limit fatigue life. The objective of this study was to investigate the effects on fatigue life of these inclusions, as part of the Crack Resistant Disk Materials task within the Ultra Safe Propulsion Project. Inclusions were carefully introduced at elevated levels in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were then performed on extracted test specimens at 650 C. Analyses were performed to compare the low-cycle fatigue lives and failure initiation sites as functions of inclusion content and fatigue conditions. Powder of the nickel-base superalloy U720 was atomized in argon at Special Metals Corporation, Inc., using production-scale high-cleanliness powder-processing facilities and handling practices. The powder was then passed through a 270-mesh screen. One portion of this powder was set aside for subsequent consolidation without introduced inclusions. Two other portions of this powder were seeded with alumina inclusions. Small, polycrystalline soft (Type 2) inclusions of about 50 mm diameter were carefully prepared and blended into one powder lot, and larger hard (Type 1) inclusions of about 150 mm mean diameter were introduced into the other seeded portion of powder. All three portions of powder were then sealed in separate containers, hot isostatically pressurized, extruded, forged into subscale disks, and heat treated. Low-cycle-fatigue specimens were then extracted, machined, and tested. Fatigue tests were performed at 650 C in closed-loop servohydraulic testing machines using induction heating and axial extensometers. All tests were continued to failure, and fractographic evaluations were performed on all specimens to determine the crack initiation sites. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface, as shown for each type of inclusion in the following bar chart. The inclusions significantly reduced fatigue life from unseeded material levels, as shown in the bar chart. These effects were found to depend on the strain range, strain ratio, and inclusion size. Tests at lower strain ranges and higher strain ratios resulted in larger effects of inclusions on life. Inclusion effects on life were thereby maximized in tests at the lowest strain range of 0.6 percent and the most positive strain ratio of 0.5. Under these conditions, small Type 2 inclusions reduced life substantially-- about 20 times, whereas large Type 1 inclusions dramatically reduced life 100 times. These results clearly demonstrate that it is essential to include the effects of inclusions for realistic predictions of disk fatigue life. Important issues, including temperature dependence, crack initiation versus propagation, surface treatments, realistic disk features and machining, and realistic disk spin testing will be addressed to accurately model inclusion effects on disk fatigue life. Fatigue life varied from well over 105 cycles for no inclusions to a little over 103 cycles for 100-micrometer inclusions. A single crack initiating at a surface-connected seeded inclusion caused failure in each case.

Gabb, Timothy P.↗