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NASA NTRS2009

Self-Assembling, Flexible, Pre-Ceramic Composite Preforms

In this innovation, light weight, high temperature, compact aerospace structures with increased design options are made possible by using self-assembling, flexible, pre-ceramic composite materials. These materials are comprised of either ceramic or carbon fiber performs, which are infiltrated with polymer precursors that convert to ceramics upon thermal exposure. The preform architecture can vary from chopped fibers formed into blankets or felt, to continuous fibers formed into a variety of 2D or 3D weaves or braids. The matrix material can also vary considerably. For demonstration purposes, a 2D carbon weave was infiltrated with a SiC polymer precursor. The green or unfired material is fabricated into its final shape while it is still pliable. It is then folded or rolled into a much more compact shape, which will occupy a smaller space. With this approach, the part remains as one continuous piece, rather than being fabricated as multiple sections, which would require numerous seals for eventual component use. The infiltrated preform can then be deployed in-situ. The component can be assembled into its final shape by taking advantage of the elasticity of the material, which permits the structure to unfold and spring into its final form under its own stored energy. The pre-ceramic composites are converted to ceramics and rigidized immediately after deployment. The final ceramic composite yields a high-temperature, high-strength material suitable for a variety of aerospace structures. The flexibility of the material, combined with its high-temperature structural capacity after rigidization, leads to a less complex component design with an increased temperature range. The collapsibility of these structures allows for larger components to be designed and used, and also offers the potential for increased vehicle performance. For the case of collapsible nozzle extensions, a larger nozzle, and thus a larger nozzle exit plane, is possible because interference with surrounding structures can be avoided in the collapsed state. The larger exit plane leads to an increase in expansion area ratio, which has the potential to increase thrust and overall rocket performance. In general, the use of advanced ceramic materials can lead to improved engine and vehicle performance. The ceramics can run hotter, so less cooling is required. Fuel to coolant ratios can be balanced more readily to reduce weight. Engine efficiency can also be increased with hotter combustion and exhaust temperatures. In addition, the ceramic composites themselves can reduce the component weight by as much as 50 percent, which can translate into greater payload for the vehicle

Jaskowiak, Martha H.↗

DOE OSTI2023

Validation of Octane Hyperboosting Phenomenon in Prenol and Structurally Related Olefinic Alcohols

Hyperboosting is a recently discovered phenomenon in which the research octane number (RON) of a blend is higher than both the neat blendstock and the neat fuel it was blended into. RON is a measure of a fuel's resistance to knock, and knock is a cause of engine inefficiency. Blends which exhibit hyperboosting are blends in which an overall improvement in engine efficiency may be expected. The first discovery of hyperboosting came from blending experiments in which prenol was blended into several different base fuels. Here, ignition delay time (IDT) measurements taken using a commercially available constant volume combustion chamber called the Advanced Fuel Ignition Delay Analyzer (AFIDA) are presented. The data show that some prenol blends have longer IDTs (lower reactivity) than either neat prenol or the base fuel, providing further evidence of hyperboosting. Additionally, more blending data is presented in which the base fuel is varied, which allows for a better understanding of hyperboosting sensitivity to chemical classes. The data indicate that aromatics may inhibit, and branched alkanes may enhance the magnitude of hyperboosting observed. Enthalpy of vaporization estimates are also given for several molecules which are blended into a 4-component surrogate. These estimates are derived from Equation of State simulations and reveal that there is no observable correlation between hyperboosting and enthalpy of vaporization. Blending data for molecules which share structural similarities with prenol are also presented. Structure property relationships are suggested, in which the double bond motif of prenol seems to play an important role in hyperboosting. This may help to understand hyperboosting and its underlying mechanism. Lastly, blending curves of surrogate blends with prenol experienced hyperboosting under lean (Homogeneous Charged Compression Ignition-HCCI) operating conditions, which validates that hyperboosting is not an artifact of the octane test methods, but inherent to the properties of prenol.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Perovskite-sensitized β-Ga 2 O 3 nanorod arrays for highly selective and sensitive NO 2 detection at high temperature

Amongst various gaseous pollutants, NO 2 is one of the major exhausts originating from fossil fuel and gas combustions in vehicle engines and power plants at high temperature. Under such a scenario, in situ and real-time gas detection and monitoring solutions are largely limited, which hinders the energy-efficient and resource-saving operations of these advanced energy systems. Herein, a new type of perovskite-sensitized β-Ga 2 O 3 nanorod-array has been successfully fabricated to detect NO x at high temperature selectively and sensitively. The demonstrated gas sensors are highly sensitive to NO 2 at 800 °C, with excellent reversible and reproducible response characteristics. Through the surface decoration of perovskite-type La 0.8 Sr 0.2 CoO 3 (LSCO) nanoparticles, the sensitivity of β-Ga 2 O 3 nanorod array gas sensors is enhanced by nearly an order of magnitude, along with much faster response dynamics. A remarkable selectivity toward oxidative gases was also demonstrated with the robust differentiation of NO 2 .

36 MATERIALS SCIENCE↗

NASA NTRS1991

An overview of the Penn State Propulsion Engineering Research Center

An overview of the Penn State Propulsion Engineering Research Center is presented. The following subject areas are covered: research objectives and long term perspective of the Center; current status and operational philosophy; and brief description of Center projects (combustion, fluid mechanics and heat transfer, materials compatibility, turbomachinery, and advanced propulsion concepts).

Merkle, Charles L.↗

NASA NTRS2011

Core Noise - Increasing Importance

This presentation is a technical summary of and outlook for NASA-internal and NASA-sponsored external research on core (combustor and turbine) noise funded by the Fundamental Aeronautics Program Subsonic Fixed Wing (SFW) Project. Sections of the presentation cover: the SFW system-level noise metrics for the 2015, 2020, and 2025 timeframes; turbofan design trends and their aeroacoustic implications; the emerging importance of core noise and its relevance to the SFW Reduced-Perceived-Noise Technical Challenge; and the current research activities in the core-noise area, with additional details given about the development of a high-fidelity combustor-noise prediction capability as well as activities supporting the development of improved reduced-order, physics-based models for combustor-noise prediction. The need for benchmark data for validation of high-fidelity and modeling work and the value of a potential future diagnostic facility for testing of core-noise-reduction concepts are indicated. The NASA Fundamental Aeronautics Program has the principal objective of overcoming today's national challenges in air transportation. The SFW Reduced-Perceived-Noise Technical Challenge aims to develop concepts and technologies to dramatically reduce the perceived aircraft noise outside of airport boundaries. This reduction of aircraft noise is critical to enabling the anticipated large increase in future air traffic. Noise generated in the jet engine core, by sources such as the compressor, combustor, and turbine, can be a significant contribution to the overall noise signature at low-power conditions, typical of approach flight. At high engine power during takeoff, jet and fan noise have traditionally dominated over core noise. However, current design trends and expected technological advances in engine-cycle design as well as noise-reduction methods are likely to reduce non-core noise even at engine-power points higher than approach. In addition, future low-emission combustor designs could increase the combustion-noise component. The trend towards high-power-density cores also means that the noise generated in the low-pressure turbine will likely increase. Consequently, the combined result from these emerging changes will be to elevate the overall importance of turbomachinery core noise, which will need to be addressed in order to meet future noise goals.

Hultgren, Lennart S.↗

NASA NTRS2002

Oxidation Behavior of GRCop-84 Copper Alloy Assessed

NASA's goal of safe, affordable space transportation calls for increased reliability and lifetimes of launch vehicles, and significant reductions of launch costs. The areas targeted for enhanced performance in the next generation of reusable launch vehicles include combustion chambers and nozzle ramps; therefore, the search is on for suitable liner materials for these components. GRCop-84 (Cu-8Cr-4Nb), an advanced copper alloy developed at the NASA Glenn Research Center in conjunction with Case Western Reserve University, is a candidate. The current liner of the Space Shuttle Main Engine is another copper alloy, NARloy-Z (Cu-3Ag-0.1Zr). It provides a benchmark against which to compare the properties of candidate successors. The thermomechanical properties of GRCop-84 have been shown to be superior, and its physical properties comparable, to those of NARloy-Z. However, environmental durability issues control longevity in this application: because copper oxide scales are not highly protective, most copper alloys are quickly consumed in oxygen environments at elevated temperatures. In consequence, NARloy-Z and most other copper alloys are prone to blanching, a degradation process that occurs through cycles of oxidation-reduction as the oxide is repeatedly formed and removed because of microscale fluctuations in the oxygen-hydrogen fuel systems of rocket engines. The Space Shuttle Main Engine lining typically degraded by blanching-induced hot spots that lead to surface roughening, pore formation, and coolant leakage. Therefore, resistance to oxidation and blanching are key requirements for second-generation reusable launch vehicle liners. The rocket engine ambient includes H2 (fuel) and H2O (combustion product) and is, hence, under reduced oxygen partial pressures. Accordingly, our studies were expanded to include oxygen partial pressures as low as 322 parts per million (ppm) at the temperatures likely to be experienced in service. A comparison of 10-hr weight gains of GRCop-84, NARloy-Z, and pure copper in 0.032, 2.2, and 100 percent oxygen from 550 to 750 C is shown. In 2.2 vol% and higher oxygen content, GRCop-84 oxidation was slower than that of NARloy-Z or Cu, but that advantage was lost or diminished in 322-ppm O2. Over longer (50-hr) exposures in 1.0 atm O2, however, the advantage of GRCop-84 increased significantly, its oxidation rate becoming approximately 10 times slower than those of Cu and NARloy-Z from 500 to 700 C. Weight gains were moderate and the kinetics parabolic for all three materials in 2.2 vol% and higher oxygen content; however, in 322-ppm O2, the scales were nonprotective below about 650 C, as reflected in linear kinetics and large weight gains. The superior oxidation resistance of GRCop-84 is likely related to the kinetics of extra oxygen consumption to form the additional oxides of Cr and Nb detected beneath the GRCop-84 oxide layer. While we continue to evaluate the blanching resistance of GRCop-84 in other tests, these oxidation results indicate that GRCop-84 is suitable as a reusable launch vehicle liner, and in applications where it is desired to use a copper alloy but without the risk of oxidative failure. Three bar charts comparing overall specific weight gains by each of the three materials studied. The top chart is for oxidation in 1.0 atm of oxygen, the middle is for 2.2% oxygen (balance argon), and the bottom is for 0.0322% oxygen. GRCop-84 outperforms the other two materials, showing the least weight gain in nearly all cases.

Thomas-Ogbuji, Linus U.↗

NASA NTRS1980

Orbit transfer vehicle engine study, phase A extension. Volume 1: Executive summary

A 1980 state-of-the-art advanced expander engine was configured that delivers near-optimum payload-performance and exhibits the simplicity reliability, and life characteristics required of the OTV mission. Engine optimization studies indicate that the performance of the conventional expander cycle engine can be improved substantially through combustion chamber surface area enhancement, thermal enhancement, turbine regeneration, and power cycle efficiency enhancement procedures. The 20K lb. thrust staged combustion engine can be adapted to operate at extended periods in the 1 to 2K lb. thrust regime. The study results indicate that long-life, high performnce operation in the low thrust mode can be achieved with minimum modifications (kitting) of the engine. Although the main contribution to mission success and crew safety stems from propulsion system redundancy, significant reliability can be gained from engine component redundancy, specific engine design features ensuring safety and reliability, including an engine health monitoring system, and from a total program approach to safety and reliability, such as that presently applied to the space shuttle.

Source record↗

NASA NTRS1997

Shock Tunnel Studies of Scramjet Phenomena 1995

Reports by the research staff and graduate students of the Mechanical Engineering Department at the University of Queensland are collected and presented. These reports cover various studies related to the advancement of scramjet technology and the operation of advanced hypervelocity shock-expansion tubes. The report topics include the experimental studies of mixing and combustion in a scramjet flow path, the measurement of integrated thrust and skin friction, and the development of a free-piston-driven expansion tunnel capable delivering a test gas at super orbital velocities.

Morgan, R. G.↗

NASA NTRS1997

Shock Tunnel Studies of Scramjet Phenomena 1994

Morgan, R. G.↗

NASA NTRS2005

Reusable Hybrid Propellant Modules for Outer-Space Transport

A report summarizes the concept of reusable hybrid propellant modules (HPMs), which would be used in outer space for long-term cryogenic storage of liquefied spacecraft-propellant gases, including for example, oxygen and hydrogen for combustion-based chemical rocket engines and xenon for electric thrusters. The HPM concept would provide the fundamental building block for an efficient, reusable in-space transportation system for both crewed and uncrewed missions. Each HPM would be equipped to implement an advanced zero-boil-off method of managing cryogenic fluids, and would include a fluid-transfer interface comprising standardized fittings that would be compatible with fittings on all supply facilities and on spacecraft to be supplied. The HPM, combined with a chemical or electric orbital transfer spacecraft, would provide an integrated propulsion system. HPMs would supply chemical propellant for time-critical transfers such as crewed missions, and utilize the more efficient electric-propulsion transfer vehicles to transport filled HPMs to the destinations and to return empty HPMs back to near-Earth orbits or other intermediate locations for replenishment and reuse. The HPM prepositioned using electric propulsion would provide the chemical propellant for the crew s return trip in a much more efficient manner than a chemical-only approach. The propellants to fill the HPMs would be delivered from the Earth or other initial supply locations to the intermediate locations by use of automated, compatible spacecraft designed specifically for that purpose. Additionally, multiple HPMs could be aggregated and positioned in orbits and on planets, moons, and asteroids to supply fluids to orbiting and interplanetary spacecraft.

Mazanek, Daniel D.↗

NASA NTRS1980

Design study of flat belt CVT for electric vehicles

A continuously variable transmission (CVT) was studied, using a novel flat belt pulley arrangement which couples the high speed output shaft of an energy storage flywheel to the drive train of an electric vehicle. A specific CVT arrangement was recommended and its components were selected and sized, based on the design requirements of a 1700 KG vehicle. A design layout was prepared and engineering calculations made of component efficiencies and operating life. The transmission efficiency was calculated to be significantly over 90% with the expected vehicle operation. A design consistent with automotive practice for low future production costs was considered, together with maintainability. The technology advancements required to develop the flat belt CVT were identified and an estimate was made of how the size of the flat belt CVT scales to larger and smaller design output torques. The suitability of the flat belt CVT for alternate application to an electric vehicle powered by an electric motor without flywheel and to a hybrid electric vehicle powered by an electric motor with an internal combustion engine was studied.

Kumm, E. L.↗

DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data (Final Report)

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components: (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine

03 NATURAL GAS↗

NASA NTRS1983

Thermal and mechanical analysis of major components for the advanced adiabatic diesel engine

The proposed design for the light duty diesel is an in-line four cylinder spark assisted diesel engine mounted transversely in the front of the vehicle. The engine has a one piece cylinder head, with one intake valve and one exhaust valve per cylinder. A flat topped piston is used with a cylindrical combustion chamber recessed into the cylinder head directly under the exhaust valve. A single ceramic insert is cast into the cylinder head to insulate both the combustion chamber and the exhaust port. A similar ceramic insert is cast into the head to insulate the intake port. A ceramic faceplate is pressed into the combustion face of the head to insulate the face of the head from hot combustion gas. The valve seats are machined directly into the ceramic faceplate for the intake valve and into the ceramic exhaust pot insert for the exhaust valve. Additional ceramic applications in the head are the use of ceramic valve guides and ceramic insulated valves. The ceramic valve guides are press fit into the head and are used for increased wear resistance. The ceramic insulated valves are conventional valves with the valve faces plasma spray coated with ceramic for insulation.

Source record↗

NASA NTRS1978

Toward scramjet aircraft

The possibility for civil, military, and remotely-piloted aviation above Mach 5 is discussed with reference to the scramjet. Actively cooled aircraft structures of low weight are described, together with jet nozzle design and combustion parameters. The scramjet is seen as operating alone or in tandem with ramjet propulsion, which would power an aircraft up to scramjet speeds. Attention is given to the specific impulse of the scramjet engine, with hydrogen as the primary fuel. Applications include: advanced reconnaissance and interceptor aircraft, strategic cruise (both aircraft and missiles), highly-maneuverable interceptor missiles, transports, aircraft-type launch vehicles, first stages for Space Shuttle launching craft, and single-stage-to-orbit vehicles. Research has focused on increasing the propulsion power of the scramjet engine, while reducing drag on the accompanying airframe.

Jones, R. A.↗

NASA NTRS1990

Optimization of the propulsion cycles for advanced shuttles. II - Performance model methodology

In 1988 computer codes from NASA and DLR were combined to analyze and optimize rocket engines for advance launch vehicles. Further effort has addressed performance propulsion parameters such as chamber pressure, cycle selection (including mixed and tripropellant cycles), nozzle extension, and new technologies. Results of the study indicate that lower dry masses can be reached with the staged combustion cycle than with the gas-generator cycle, using oxygen/hydrogen at relatively high mixture ratio (7:1) and modest chamber pressure (220 bar). For low dry masses the staged combustion cycle is only excelled by the dual-expander cycle using hydrogen and propane as fuels. The emphasis here is to explain the procedure and boundary conditions used for the analysis and the variety of configurations treated, as well as to demonstrate the methods used by presenting some of the major results.

Manski, Detlef↗

NASA NTRS2000

Energetic Combustion Devices for Aerospace Propulsion and Power

Chemical reactions have long been the mainstay thermal energy source for aerospace propulsion and power. Although it is widely recognized that the intrinsic energy density limitations of chemical bonds place severe constraints on maximum realizable performance, it will likely be several years before systems based on high energy density nuclear fuels can be placed into routine service. In the mean time, efforts to develop high energy density chemicals and advanced combustion devices which can utilize such energetic fuels may yield worthwhile returns in overall system performance and cost. Current efforts in this vein are being carried out at NASA MSFC under the direction of the author in the areas of pulse detonation engine technology development and light metals combustion devices. Pulse detonation engines are touted as a low cost alternative to gas turbine engines and to conventional rocket engines, but actual performance and cost benefits have yet to be convincingly demonstrated. Light metal fueled engines also offer potential benefits in certain niche applications such as aluminum/CO2 fueled engines for endo-atmospheric Martian propulsion. Light metal fueled MHD generators also present promising opportunities with respect to electric power generation for electromagnetic launch assist. This presentation will discuss the applications potential of these concepts with respect to aero ace propulsion and power and will review the current status of the development efforts.

Litchford, Ron J.↗

NASA NTRS2004

Transitioning a Fundamental Research Program to Align with the NASA Exploration Initiative-Perspectives from Microgravity Combustion Science and Fluid Physics

A new Vision for Space Exploration was announced earlier this year by U.S. President George W. Bush. NASA has evaluated on-going programs for strategic alignment with this vision. The evaluation proceeded at a rapid pace and is resulting in changes to the scope and focus of experimental research that will be conducted in support of the new vision. The existing network of researchers in the physical sciences - a highly capable, independent, and loosely knitted community - typically have shared conclusions derived from their work within appropriate discipline-specific peer reviewed journals and publications. The initial result of introducing this Vision for Space Exploration has been to shift research focus from a broad coverage of numerous, widely varying topics into a research program focused on a nearly-singular set of supporting research objectives to enable advances in space exploration. Two of these traditional physical science research disciplines, Combustion Science and Fluid Physics, are implementing a course adjustment from a portfolio dominated by "Fundamental Science Research" to one focused nearly exclusively on supporting the Exploration Vision. Underlying scientific and engineering competencies and infrastructure of the Microgravity Combustion Science and Fluid Physics disciplines do provide essential research capabilities to support the contemporary thrusts of human life support, radiation countermeasures, human health, low gravity research for propulsion and materials and, ultimately, research conducted on the Moon and Mars. A perspective on how these two research disciplines responded to the course change will be presented. The relevance to the new NASA direction is provided, while demonstrating through two examples how the prior investment in fundamental research is being brought to bear on solving the issues confronting the successful implementation of the exploration goals.

Sutliff, Thomas J.↗