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NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

The research and development activities reported in this publication were carried out under NASA Aeronautics Research Institute (NARI) funded project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing." The objective of the project was to conduct evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. The results of the activities are described in three part report. The first part of the report contains the data and analysis of engine system trade studies, which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. The technical scope of activities included an assessment of the feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composites, which were accomplished by fabricating prototype engine components and testing them in simulated engine operating conditions. The manufacturing process parameters were developed and optimized for polymer and ceramic composites (described in detail in the second and third part of the report). A number of prototype components (inlet guide vane (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included turbine nozzle components. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

acoustic liners↗
NASA NTRS1999

Three Dimensional Model Simulation of Constituent Transport in the Lowermost Stratosphere

The composition, transport and photochemistry of the lowermost stratosphere, i.e., that part of the atmosphere which is above the tropopause, poleward of the tropics, and at potential temperature lower than the potential temperature of the tropical tropopause (about 380K) are of practical interest for understanding global ozone behavior. Because this region is a transition between transport regimes characterized by different scales of dynamics, it is especially difficult to model realistically. Through comparisons of observations of ozone, carbon dioxide and water vapor with results from a chemistry and transport model using winds from a global meteorological assimilation system, we have established that the model provides a good representation of several important aspects of constituent behavior. These include the constituent gradients near the tropopause as well as the annual cycle of constituents and the altitude dependence of the annual cycle from the tropopause into the middle stratosphere. This talk draws together these results to form a unified picture of transport into the lowermost extratropical stratosphere. In particular, the importance of convective transport to the distribution of both short-lived, and long-lived constituents in the lowermost stratosphere will be evaluated.

Douglass, Anne R.↗
NASA NTRS2011

Aromatic Structure in Simulates Titan Aerosol

Observations of Titan by the Cassini Composite Infrared Spectrometer (CIRS) between 560 and 20 per centimeter (approximately 18 to 500 micrometers) have been used to infer the vertical variations of Titan's ice abundances, as well as those of the aerosol from the surface to an altitude of 300 km [1]. The aerosol has a broad emission feature centered approximately at 140 per centimeter (71 micrometers). As seen in Figure 1, this feature cannot be reproduced using currently available optical constants from laboratory-generated Titan aerosol analogs [2]. The far-IR is uniquely qualified for investigating low-energy vibrational motions within the lattice structures of COITIDlex aerosol. The feature observed by CIRS is broad, and does not likely arise from individual molecules, but rather is representative of the skeletal movements of macromolecules. Since Cassini's arrival at Titan, benzene (C6H6) has been detected in the atmosphere at ppm levels as well as ions that may be polycyclic aromatic hydrocarbons (PAHs) [3]. We speculate that the feature may be a blended composite that can be identified with low-energy vibrations of two-dimensional lattice structures of large molecules, such as PAHs or nitrogenated aromatics. Such structures do not dominate the composition of analog materials generated from CH4 and N2 irradiation. We are performing studies forming aerosol analog via UV irradiation of aromatic precursors - specifically C6H6 - to understand how the unique chemical architecture of the products will influence the observable aerosol characteristics. The optical and chemical properties of the aromatic analog will be compared to those formed from CH4/N2 mixtures, with a focus on the as-yet unidentified far-IR absorbance feature. Preliminary results indicate that the photochemically-formed aromatic aerosol has distinct chemical composition, and may incorporate nitrogen either into the ring structure or adjoined chemical groups. These compositional differences are demonstrated in the aerosol mass spectra shown in Figure 2. The aromatic aerosol also demonstrates strong chemical reactivity when exposed to laboratory air, indicating substantial stored chemical potential. Oxidatoin and solubility studies wil be presented and implicatoins for prebiotic chemistry o nTitan will be discussed.

Trainer, Melissa G.↗
NASA NTRS1996

Reliability, Risk and Cost Trade-Offs for Composite Designs

Risk and cost trade-offs have been simulated using a probabilistic method. The probabilistic method accounts for all naturally-occurring uncertainties including those in constituent material properties, fabrication variables, structure geometry and loading conditions. The probability density function of first buckling load for a set of uncertain variables is computed. The probabilistic sensitivity factors of uncertain variables to the first buckling load is calculated. The reliability-based cost for a composite fuselage panel is defined and minimized with respect to requisite design parameters. The optimization is achieved by solving a system of nonlinear algebraic equations whose coefficients are functions of probabilistic sensitivity factors. With optimum design parameters such as the mean and coefficient of variation (representing range of scatter) of uncertain variables, the most efficient and economical manufacturing procedure can be selected. In this paper, optimum values of the requisite design parameters for a predetermined cost due to failure occurrence are computationally determined. The results for the fuselage panel analysis show that the higher the cost due to failure occurrence, the smaller the optimum coefficient of variation of fiber modulus (design parameter) in longitudinal direction.

Shiao, Michael C.↗
NASA NTRS2017

Advanced Ceramic Matrix Composites: Science and Technology of Materials, Design, Applications, Performance and Integration

Overview of NASA Transformational Tools and Technologies Project's 2700F CMC/EBC Technology Challenge J. Hurst, NASA (National Aeronautics and Space Administration, Glenn Research Center, Cleveland, OH USA Key Words: ceramic matrix composites (CMCs), SiC/SiC composites, environmental barrier coatings (EBCs), CMC modeling, simulated engine testing As advanced gas turbine engine designs continue to move toward both higher operating temperatures and increased pressures, materials capable of functioning under these extreme conditions are being sought by both government and industry. As part of its mission, the NASA's Transformational Tools and Technologies Project, under the auspices of NASA's Aeronautics Research Mission Directorate, has been pursuing a five year Technology Challenge problem. This challenge problem has sought to develop high temperature materials for turbine engines that enable a 6% reduction in fuel burn for commercial aircraft, compared to current SOA materials. Specifically this is accomplished by the development and demonstration of a ceramic matrix composite (CMC) and environmental barrier coating (EBC) system capable of sustained performance at temperature of 2700F. The NASA Glenn Research Center has continued its two decade long interest in CMC/EBCs technology by pursuing this 2700F performance goal. This ambitious effort included an array of vendors, universities and engine companies. Included in this challenge was fiber development, fiber architecture considerations, ceramic matrix composition, environmental barrier compositions and processing routes as well as test development. Evaluation of the CMC/EBC materials included a variety of testing, from coupon testing for strength and creep resistance, to testing aimed at determining material behavior under more engine-like conditions. The development and validation of thermomechanical models and computational tools for design, analysis, and life prediction, have been an important part of this effort as well. Simulated engine testing of vane subcomponents by P&W was the final step following years of development. In addition to achieving the temperature goals and enhanced durability performance of the Tech Challenge, an additional goal achieved by this work was reaching a Technology Readiness Level of 5 for the 3-D CMC/EBC system. As this five year Technical Challenge comes to a conclusion, future development interests in environmental barrier coatings and environmental modeling are discussed.

SiC/SiC composites↗
NASA NTRS2001

Large Eddy Simulation of Gravitational Effects on Transitional and Turbulent Gas-Jet Diffusion Flames

The basic objective of this work is to assess the influence of gravity on "the compositional and the spatial structures" of transitional and turbulent diffusion flames via large eddy simulation (LES), and direct numerical simulation (DNS). The DNS is conducted for appraisal of the various closures employed in LES, and to study the effect of buoyancy on the small scale flow features. The LES is based on our "filtered mass density function"' (FMDF) model. The novelty of the methodology is that it allows for reliable simulations with inclusion of "realistic physics." It also allows for detailed analysis of the unsteady large scale flow evolution and compositional flame structure which is not usually possible via Reynolds averaged simulations.

Givi, Peyman↗
NASA NTRS2015

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing, Part II: Additive Manufacturing and Characterization of Polymer Composites

This publication is the second part of the three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides-Ultem 9085 and experimental Ultem 1000 mixed with 10% chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25 to 31%. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties. A preliminary modeling was also initiated to predict the mechanical properties of FDM-printed Ultem 9085 coupons in relation to varied raster angles and void contents, using the GRC-developed MAC/GMC program.

Polymer↗
NASA NTRS2015

Additive Manufacturing of Ultem Polymers and Composites

The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimdes Ultem 9085 and experimental Ultem 1000 filled with 10 chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25-31. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties.

Polymer↗
NASA NTRS2015

Additive Manufacturing and Characterization of Ultem Polymers and Composites

The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides - Ultem 9085 and experimental Ultem 1000 mixed with 10 percent chopped carbon fiber. A property comparison between FDM-printed and injection-molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25-31 percent. Coupons of Ultem 9085 and experimental Ultem 1000 composites were tested at room temperature and 400 degrees Fahrenheit to evaluate their corresponding mechanical properties.

Polymers↗
NASA NTRS2003

Application of Probabilistic Analysis to Aircraft Impact Dynamics

Full-scale aircraft crash simulations performed with nonlinear, transient dynamic, finite element codes can incorporate structural complexities such as: geometrically accurate models; human occupant models; and advanced material models to include nonlinear stressstrain behaviors, laminated composites, and material failure. Validation of these crash simulations is difficult due to a lack of sufficient information to adequately determine the uncertainty in the experimental data and the appropriateness of modeling assumptions. This paper evaluates probabilistic approaches to quantify the uncertainty in the simulated responses. Several criteria are used to determine that a response surface method is the most appropriate probabilistic approach. The work is extended to compare optimization results with and without probabilistic constraints.

Lyle, Karen H.↗
NASA NTRS1981

Low-velocity impact tests on fibrous composite sandwich structures

The effect of low-velocity projectile impact on the load-carrying ability of the composite sandwich structural components is investigated experimentally, the impact simulating the damage caused by runway debris and the accidental dropping of hand tools during servicing on secondary aircraft structures made with composites. The sandwich-type beam specimens were fabricated with graphite/epoxy face sheets, aluminum honeycomb core, and a steel (back) plate. A four-point beam-loading apparatus was used, and the ultimate strength, ultimate strain, and residual strength of the composites were determined. A faired curve is presented indicating the lower bound of the failure threshold for each of the laminate configurations tested in compression and tension as a function of the projectile impact energy. It is shown that strength degradation due to impact is dependent on the laminate configuration and the fiber/matrix combination. The laminates having more angle plies near the impact surface and unidirectional plies elsewhere seem to show extensive interply and intraply fiber delaminations at failure relative to the laminates with a cross-ply on the impact surface.

Sharma, A. V.↗
NASA NTRS2013

Can Fractional Crystallization of a Lunar Magma Ocean Produce the Lunar Crust?

New techniques enable the study of Apollo samples and lunar meteorites in unprecedented detail, and recent orbital spectral data reveal more about the lunar farside than ever before, raising new questions about the supposed simplicity of lunar geology. Nevertheless, crystallization of a global-scale magma ocean remains the best model to account for known lunar lithologies. Crystallization of a lunar magma ocean (LMO) is modeled to proceed by two end-member processes - fractional crystallization from (mostly) the bottom up, or initial equilibrium crystallization as the magma is vigorously convecting and crystals remain entrained, followed by crystal settling and a final period of fractional crystallization [1]. Physical models of magma viscosity and convection at this scale suggest that both processes are possible. We have been carrying out high-fidelity experimental simulations of LMO crystallization using two bulk compositions that can be regarded as end-members in the likely relevant range: Taylor Whole Moon (TWM) [2] and Lunar Primitive Upper Mantle (LPUM) [3]. TWM is enriched in refractory elements by 1.5 times relative to Earth, whereas LPUM is similar to the terrestrial primitive upper mantle, with adjustments made for the depletion of volatile alkalis observed on the Moon. Here we extend our earlier equilibrium-crystallization experiments [4] with runs simulating full fractional crystallization

Rapp, Jennifer F.↗
NASA NTRS2004

The Response of the North Atlantic Bloom to NAO Forcing

Results from the climatologically forced coupled ice/ocean/biogeochemical model that covers the Arctic and North Atlantic Oceans are presented and compared to the chlorophyll fields of satellite-derived ocean color measurements. Biogeochemical processes in the model are determined from the interactions among four phytoplankton functional groups (diatoms, chlorophytes, cyanobacteria and coccolithophores) and four nutrients (nitrate, ammonium, silicate and dissolved iron). The model simulates the general large-scale pattern in April, May and June, when compared to both satellite-derived and in situ observations. The subpolar North Atlantic was cool in the 1980s and warm in the latter 1990s, corresponding to the CZCS and SeaWiFS satellite observing periods, respectively. The oceanographic conditions during these periods resemble the typical subpolar upper ocean response to the NAO+ and NAO-phases, respectively. Thus, we use the atmospheric forcing composites from the two NAO phases to simulate the variability of the mid-ocean bloom during the satellite observing periods. The model results show that when the subpolar North Atlantic is cool, the NAO+ case, more nutrients are available in early spring than when the North Atlantic is warm, the NAO-case. However, the NAO+ simulation produces a later bloom than the NAO-simulation. This difference in the bloom times is also identified in SeaWiFS and CZCS satellite measurements. In the model results, we can trace the difference to the early diatom bloom due to a warmer upper ocean. The higher nutrient abundance in the NAO+ case did not provide larger total production than in the NAO- case, instead the two cases had a comparable area averaged amplitude. This leads us to conclude that in the subpolar North Atlantic, the timing of the spring phytoplankton bloom depends on surface temperature and the magnitude of the bloom is not significantly impacted by the nutrient abundance.

Mizoguchi, Ken-Ichi↗
NASA NTRS1992

Instrumental and observational requirements for space-based imaging of magnetospheric emissions

Simulated images of extreme ultraviolet (EUV) emissions from energetic outflowing ions have been constructed to study techniques for remotely sensing the dynamic behavior of hot plasmas in the near-Earth environment. These calculations include realistic assumptions about the energetic ion outflow from high latitudes and take into account the effects of cold plasmaspheric and ionospheric ions. The energetic ion outflow is determined from a statistical study based on five years of measurements from the Energetic Ion Composition Spectrometer on Dynamics Explorer 1. The simulated images change significantly with viewing geometry and certain spacecraft locations are clearly favorable for observing emissions from energetic ions. For example, for a near equatorial orbit, viewing locations greater than 9 Earth radii are required to observe outflowing ions above the cold plasmaspheric background. We will discuss other important considerations for magnetospheric imaging including the sensitivity requirements of the detector. In particular, we consider the performance of multi-layer optics for EUV wavelengths.

Robinson, R. M.↗
NASA NTRS2022

Parallel Grand-Canonical Monte Carlo (ParaGrandMC) User’s Manual Version 2.0

This manual describes the commands and command line options for the Parallel Grand Canonical Monte Carlo version 2.0 (ParaGrandMC.2.0) simulation code. This is a highly scalable parallel FORTRAN 2003 code for simulating the thermodynamic evolution of materials at the atomic level, and predicting their thermodynamic state, phase diagram, chemical composition and mechanical properties. The code is specifically designed to simulate multi-component alloy systems, predict solid-state phase transformations such as austenite-martensite transformations, precipitate formation, recrystallization, capillary effects at interfaces, surface absorption, etc., which can aid the design of novel metallic alloys. While the software is mainly tailored for modeling metal alloys, it can also be used for other types of solid-state systems, and to some degree for liquid or gaseous systems, including multiphase systems forming solid-liquid-gas interfaces. In addition to performing Monte Carlo (MC) simulations, the code can also perform Molecular Dynamics (MD) and Langevin Dynamics (LD) simulations, which can be combined and interchanged with MC for faster and more efficient system evolution. A detailed description of the MC part of the code is provided in the NASA ParaGrandMC report: NASA/CR–2016-219202; http://www.sti.nasa.gov.

High performance computing↗
NASA NTRS1986

The effects of radiation on the interlaminar fracture toughness of a graphite/epoxy composite

An experimental study is made of the effect of electron irradiation (10 to the 10th rad), simulating a 30-year geosynchronous orbit exposure, on the fracture toughness of a graphite/epoxy composite, T300/934. The double cantilever beam (DBC) test is used to determine Mode I (peel) critical strain energy release rate and the edge delamination tension (EDT) test is used to determine mixed Mode I and II (peel and shear) critical strain energy release rate. It is found that the electron interaction of the epoxy matrix material enhances the fracture toughness properties of the composite and that the test temperature has a significant effect on the fracture toughness of both baseline and irradiated material.

Funk, J. G.↗
NASA NTRS2014

Computational Reduction of Specimen Noise to Enable Improved Thermography Characterization of Flaws in Graphite Polymer Composites

Flaw detection and characterization with thermographic techniques in graphite polymer composites are often limited by localized variations in the thermographic response. Variations in properties such as acceptable porosity, fiber volume content and surface polymer thickness result in variations in the thermal response that in general cause significant variations in the initial thermal response. These result in a "noise" floor that increases the difficulty of detecting and characterizing deeper flaws. A method is presented for computationally removing a significant amount of the "noise" from near surface porosity by diffusing the early time response, then subtracting it from subsequent responses. Simulations of the thermal response of a composite are utilized in defining the limitations of the technique. This method for reducing the data is shown to give considerable improvement characterizing both the size and depth of damage. Examples are shown for data acquired on specimens with fabricated delaminations and impact damage.

Winfree, William P.↗
NASA NTRS1989

Aeolian processes on Venus

This review assesses the potential aeolian regime on Venus as derived from spacecraft observations, laboratory simulations, and theoretical considerations. The two requirements for aeolian processes (a supply of small, loose particles and winds of sufficient strength to move them) appear to be met on Venus. Venera 9, 10, 13, and 14 images show particles considered to be sand and silt size on the surface. In addition, dust spurts (grains 5 to 50 microns in diameter) observed via lander images and inferred from the Pioneer-Venus nephalometer experiments suggest that the particles are loose and subject to movement. Although data on near surface winds are limited, measurements of 0.3 to 1.2 m/sec from the Venera lander and Pioneer-Venus probes appear to be well within the range required for sand and dust entrainment. Aeolian activity involves the interaction of the atmosphere, lithosphere, and loose particles. Thus, there is the potential for various physical and chemical weathering processes that can effect not only rates of erosion, but changes in the composition of all three components. The Venus Simulator is an apparatus used to simulate weathering under venusian conditions at full pressure (to 112 bars) and temperature (to 800 K). In one series of tests, the physical modifications of windblown particles and rock targets were assessed and it was shown that particles become abraded even when moved by gentle winds. However, little abrasion occurs on the target faces. Thus, compositional signatures for target rocks may be more indicative of the windblown particles than of the bedrock. From these and other considerations, aeolian modifications of the venusian surface may be expected to occur as weathering, erosion, transportation, and deposition of surficial materials. Depending upon global and local wind regimes, there may be distinctive sources and sinks of windblown materials. Radar imaging, especially as potentially supplied via the Magellan mission, may enable the identification of such areas on Venus.

Greeley, Ronald↗