Materials engineering
Thermal diffusivity measurement, thermoelectric properties of graphite alloys and compounds, superconductivity in tungsten films, and gas pump based on thermal transpiration
Altman, M.↗
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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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Variable thrust ion engine utilizing thermally decomposable solid fuel Patent
Variable thrust ion engine using thermal decomposition of solid cesium compound to produce propulsive vapor
Petrick, E. N.↗
Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet Molding Compound
Although polyimide based composites have been used for many years in a wide variety of elevated temperature applications, very little work has been done to examine the durability and damage behavior under more prototypical thermomechanical fatigue (TMF) loadings. Synergistic effects resulting from simultaneous temperature and load cycling can potentially lead to enhanced, if not unique, damage modes and contribute to a number of nonlinear deformation responses. The goal of this research was to examine the effects of a TMF loading spectrum, representative of a gas turbine engine compressor application, on a polyimide sheet molding compound (SMC). High performance SMCs present alternatives to prepreg forms with great potential for low cost component production through less labor intensive, more easily automated manufacturing. To examine the issues involved with TMF, a detailed experimental investigation was conducted to characterize the durability of a T650-35/PMR-15 SMC subjected to TMF mission cycle loadings. Fatigue damage progression was tracked through macroscopic deformation and elastic stiffness. Additional properties, such as the glass transition temperature (T(sub g) and dynamic mechanical properties were examined. The fiber distribution orientation was also characterized through a detailed quantitative image analysis. Damage tolerance was quantified on the basis of residual static tensile properties after a prescribed number of TMF missions. Detailed microstructural examinations were conducted using optical and scanning electron microscopy to characterize the local damage. The imposed baseline TMF missions had only a modest impact on inducing fatigue damage with no statistically significant degradation occurring in the measured macroscopic properties. Microstructural damage was, however, observed subsequent to 100 h of TMF cycling which consisted primarily of fiber debonding and transverse cracking local to predominantly transverse fiber bundles. The TMF loadings did introduce creep related effects (strain accumulation) which led to rupture in some of the more aggressive stress scenarios examined. In some cases this creep behavior occurred at temperatures in excess of 150 C below commonly cited values for T(sub g). Thermomechanical exploratory creep tests revealed that the SMC was subject to time dependent deformation at stress/temperature thresholds of 150 MPa/230 C and 170 MPa/180 C.
Castelli, Michael G.↗
Crystal Growth of Device Quality Gaas in Space
The GaAs research evolves about these key thrust areas. The overall program combines: (1) studies of crystal growth on novel approaches to engineering of semiconductor material (i.e., GaAs and related compounds); (2) investigation and correlation of materials properties and electronic characteristics on a macro- and microscale; and (3) investigation of electronic properties and phenomena controlling device applications and device performance. This effort is aimed at the essential ground-based program which would insure successful experimentation with and eventually processing of GaAs in near zero gravity environment. It is believed that this program addresses in a unique way materials engineering aspects which bear directly on the future exploitation of the potential of GaAs and related materials in device and systems applications.
Gatos, H. C.↗
Forced Mixer Nozzle Optimization
Computational fluid dynamic (CFD) and computational acoustic analyses (CAA) were performed for a TFE731-40 compound nozzle, a TFE731-60 mixer nozzle and an Energy Efficient Engine (E(sup 3)) mixer nozzle for comparison with available data. The CFD analyses were performed with a three dimensional, Navier-Stokes solution of the flowfield on an unstructured grid using the RAMPANT program. The CAA analyses were performed with the NASA Glenn MGB program using a structured grid. A successful aerodynamic solution for the TFE731-40 compound nozzle operating statically was obtained, simulating an engine operating on a test stand. Analysis of the CFD results of the TFE731-40 with the MGB program produced predicted sound power levels that agree quite well with the measured data front full-scale static engine tests. Comparison of the predicted sound pressure with the data show good agreement near the jet axis, but the noise levels are overpredicted at angles closer to the inlet. The predicted sound power level for the TFE731-60 did not agree as well with measured static engine data as the TFE731-40. Although a reduction in the predicted noise level due to the mixed flow was observed, the reduction was not as significant as the measured data. The analysis of the V2 mixer from the E(sup 3) study showed that peak temperatures predicted in the mixer exit flowfield were within 5 percent of the values measured by the exit probes. The noise predictions of the V2 mixer nozzle tended to be 3-5 dB higher in peak noise level than the measurements. In addition, the maximum frequency of the noise was also overpredicted. An analysis of the 3 candidate mixer nozzle configurations demonstrated the feasibility of using centerbody lobes and porosity to improve mixing efficiency. A final configuration was designed with a predicted thermal mixing efficiency that was 5 percent higher than the 3 candidate mixers. The results of the MGB noise calculations show that the final design will exceed the design goal of a 3 dB reduction in noise as compared to the baseline TFE731-40.
Sheoran, Yogi↗
Surveyor Vernier engine fuel blend - A constrained optimization.
Propellant composition variation for improving cooling characteristics of Surveyor vernier propulsion system
PROPELLANT COMPOUND↗
A Collaborative Analysis Tool for Integrated Hypersonic Aerodynamics, Thermal Protection Systems, and RBCC Engine Performance for Single Stage to Orbit Vehicles
Presented is a computer-based tool that connects several disciplines that are needed in the complex and integrated design of high performance reusable single stage to orbit (SSTO) vehicles. Every system is linked to every other system, as is the case of SSTO vehicles with air breathing propulsion, which is currently being studied by NASA. An RBCC propulsion system integrates airbreathing and rocket propulsion into a single engine assembly enclosed within a cowl or duct. A typical RBCC propulsion system operates as a ducted rocket up to approximately Mach 3. Then there is a transition to a ramjet mode for supersonic-to-hypersonic acceleration. Around Mach 8 the engine transitions to a scramjet mode. During the ramjet and scramjet modes, the integral rockets operate as fuel injectors. Around Mach 10-12 (the actual value depends on vehicle and mission requirements), the inlet is physically closed and the engine transitions to an integral rocket mode for orbit insertion. A common feature of RBCC propelled vehicles is the high degree of integration between the propulsion system and airframe. At high speeds the vehicle forebody is fundamentally part of the engine inlet, providing a compression surface for air flowing into the engine. The compressed air is mixed with fuel and burned. The combusted mixture must be expanded to an area larger than the incoming stream to provide thrust. Since a conventional nozzle would be too large, the entire lower after body of the vehicle is used as an expansion surface. Because of the high external temperatures seen during atmospheric flight, the design of an airbreathing SSTO vehicle requires delicate tradeoffs between engine design, vehicle shape, and thermal protection system (TPS) sizing in order to produce an optimum system in terms of weight (and cost) and maximum performance. To adequately determine the performance of the engine/vehicle, the Hypersonic Flight Inlet Model (HYFIM) module was designed to interface with the RBCC engine model. HYFIM performs the aerodynamic analysis of forebodies and inlet characteristics of RBCC powered SSTO launch vehicles. HYFIM is applicable to the analysis of the ramjet/scramjet engine operations modes (Mach 3-12), and provides estimates of parameters such as air capture area, shock-on-lip Mach number, design Mach number, compression ratio, etc., based on a basic geometry routine for modeling axisymmetric cones, 2-D wedge geometries. HYFIM also estimates the variation of shock layer properties normal to the forebody surface. The thermal protection system (TPS) is directly linked to determination of the vehicle moldline and the shaping of the trajectory. Thermal protection systems to maintain the structural integrity of the vehicle must be able to mitigate the heat transfer to the structure and be lightweight. Herein lies the interdependency, in that as the vehicle's speed increases, the TPS requirements are increased. And as TPS masses increase the effect on the propulsion system and all other systems is compounded. The need to analyze vehicle forebody and engine inlet is critical to be able to design the RBCC vehicle. To adequately determine insulation masses for an RBCC vehicle, the hypersonic aerodynamic environment and aeroheating loads must be calculated and the TPS thicknesses must be calculated for the entire vehicle. To accomplish this an ascent or reentry trajectory is obtained using the computer code Program to Optimize Simulated Trajectories (POST). The trajectory is then used to calculate the convective heat rates on several locations on the vehicles using the Miniature Version of the JA70 Aerodynamic Heating Computer Program (MINIVER). Once the heat rates are defined for each body point on the vehicle, then insulation thicknesses that are required to maintain the vehicle within structural limits are calculated using Systems Improved Numerical Differencing Analyzer (SINDA) models. If the TPS masses are too heavy for the performance of the vehicle the process may be repeated altering the trajectory or some other input to reduce the TPS mass. E-PSURBCC is an "engine performance" model and requires the specification of inlet air static temperature and pressure as well as Mach number (which it pulls from the HYFIM and POST trajectory files), and calculates the corresponding stagnation properties. The engine air flow path geometry includes inlet, a constant area section where the rocket is positioned, a subsonic diffuser, a constant area afterburner, and either a converging nozzle or a converging-diverging nozzle. The current capabilities of E-PSURBCC ejector and ramjet mode treatment indicated that various complex flow phenomena including multiple choking and internal shocks can occur for combinations of geometry/flow conditions. For a given input deck defining geometry/flow conditions, the program first goes through a series of checks to establish whether the input parameters are sound in terms of a solution path. If the vehicle/engine performance fails mission goals, the engineer is able to collaboratively alter the vehicle moldline to change aerodynamics, or trajectory, or some other input to achieve orbit. The problem described is an example of the need for collaborative design and analysis. RECIPE is a cross-platform application capable of hosting a number of engineers and designers across the Internet for distributed and collaborative engineering environments. Such integrated system design environments allow for collaborative team design analysis for performing individual or reduced team studies. To facilitate the larger number of potential runs that may need to be made, RECIPE connects the computer codes that calculate the trajectory data, aerodynamic data based on vehicle geometry, heat rate data, TPS masses, and vehicle and engine performance, so that the output from each tool is easily transferred to the model input files that need it.
Stanley, Thomas Troy↗
The design and development of a mixer compound exhaust system for a quiet clean general aviation turbofan
Lower engine fuel consumption has become a dominant factor in turbofan engine design due to rapidly increasing fuel costs. One engine component with a large impact on engine performance is the exhaust system. Previous exhaust system studies have demonstrated the significant exhaust system efficiency gains available through mixing of the core and bypass flows. Typically, a large, costly rig and engine program are required to develop and optimize these gains. The purpose of this paper is to present the results of the low-cost design system used for the quiet, clean general aviation turbofan mixer nozzle design and development. The scale model and full-scale engine test results confirm the predicted 3 to 5% reduction in cruise fuel consumption. This unique design system, which is based on integrating advanced three-dimensional viscous numerical methods with empirical optimization techniques, is summarized and detailed comparisons with test data are presented. The ability to accurately predict relative performance of mixer systems with substantially reduced development time and cost savings is demonstrated.
Blackmore, W. L.↗
Status and prognosis for alternative engine materials
The current state of research and development of new materials for advanced aircraft engines is reviewed. The advantages and disadvantages of intermetallic compounds and refractory metals as replacements for today's nickel-base alloys are discussed along with some results of research directed at overcoming some of the problems which restrict their application. It is concluded that continuous fiber reinforced intermetallic matrix composites offer one of the best chances for success. However, major technical barriers still exist, especially in the development of suitable fibers. The introduction of these materials into aircraft engines is expected to take in excess of 5 to 10 years.
Stephens, Joseph R.↗
Status and prognosis for alternative engine materials
The current state of research and development of new materials for advanced aircraft engines is reviewed. The advantages and disadvantages of intermetallic compounds and refractory metals as replacements for today's nickel-base alloys are discussed along with some results of research directed at overcoming some of the problems which restrict their application. It is concluded that continuous fiber reinforced intermetallic matrix composites offer one of the best chances for success. However, major technical barriers still exist, especially in the development of suitable fibers. The introduction of these materials into aircraft engines is expected to take in excess of 5 to 10 years.
Stephens, Joseph R.↗
Use of highly reactive chemical additives to improve afterburner performance at altitude
Liquid hydrogen and aluminum trimethyl as highly reactive chemical additives in turbojet afterburner to promote fuel combustion process
LIQUID HYDROGEN↗
Crystal growth of device quality GaAs in space
GaAs device technology has recently reached a new phase of rapid advancement, made possible by the improvement of the quality of GaAs bulk crystals. At the same time, the transition to the next generation of GaAs integrated circuits and optoelectronic systems for commercial and government applications hinges on new quantum steps in three interrelated areas: crystal growth, device processing and device-related properties and phenomena. Special emphasis is placed on the establishment of quantitative relationships among crystal growth parameters-material properties-electronic properties and device applications. The overall program combines studies of crystal growth on novel approaches to engineering of semiconductor material (i.e., GaAs and related compounds); investigation and correlation of materials properties and electronic characteristics on a macro- and microscale; and investigation of electronic properties and phenomena controlling device applications and device performance.
Gatos, H. C.↗
Crystal growth of device quality GaAs in space
The crystal growth, device processing and device related properties and phenomena of GaAs are investigated. Our GaAs research evolves about these key thrust areas. The overall program combines: (1) studies of crystal growth on novel approaches to engineering of semiconductor materials (i.e., GaAs and related compounds); (2) investigation and correlation of materials properties and electronic characteristics on a macro- and microscale; (3) investigation of electronic properties and phenomena controlling device applications and device performance. The ground based program is developed which would insure successful experimentation with and eventually processing of GaAs in a near zero gravity environment.
Gatos, H. C.↗
Screw expander for light duty diesel engines
Preliminary selection and sizing of a positive displacement screw compressor-expander subsystem for a light-duty adiabatic diesel engine; development of a mathematical model to describe overall efficiencies for the screw compressor and expander; simulation of operation to establish overall efficiency for a range of design parameters and at given engine operating points; simulation to establish potential net power output at light-duty diesel operating points; analytical determination of mass moments of inertia for the rotors and inertia of the compressor-expander subsystem; and preparation of engineering layout drawings of the compressor and expander are discussed. As a result of this work, it was concluded that the screw compressor and expander designed for light-duty diesel engine applications are viable alternatives to turbo-compound systems, with acceptable efficiencies for both units, and only a moderate effect on the transient response.
Source record↗
Formaldehyde Concentration Dynamics of the International Space Station Cabin Atmosphere
Formaldehyde presents a significant challenge to maintaining cabin air quality on board crewed spacecraft. Generation sources include offgassing from a variety of non-metallic materials as well as human metabolism. Because generation sources are pervasive and human health can be affected by continual exposure to low concentrations, toxicology and air quality control engineering experts jointly identified formaldehyde as a key compound to be monitored as part the International Space Station's (ISS) environmental health monitoring and maintenance program. Data acquired from in-flight air quality monitoring methods are the basis for assessing the cabin environment's suitability for long-term habitation and monitoring the performance of passive and active controls that are in place to minimize crew exposure. Formaldehyde concentration trends and dynamics served in the ISS cabin atmosphere are reviewed implications to present and future flight operations discussed.
Perry, J. L.↗
Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event
Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.
Michael W Lee↗
Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event
Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.
Michael Lee↗
Advanced automotive diesel engine system study
A conceptual study of an advanced automotive diesel engine is discussed. The engine concept selected for vehicle installation was a supercharged 1.4 liter, 4 cylinder spark assisted diesel of 14:1 compression ratio. A compounding unit consisting of a Lysholm compressor and expander is connected to the engine crankshaft by a belt drive. The inlet air charge is heated by the expander exhaust gas via a heat exchanger. Four levels of technology achievement on the selected engine concept were evaluated, from state-of-the-art to the ideal case. This resulted in the fuel economy increasing from 53.2 mpg to 81.7 mpg, and the 0-60 mph time decreasing from 17.6 seconds to 10.9 seconds.
Source record↗