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NASA NTRS2009

Analysis of Potential for Titanium Liner Buckling after Proof in a Large Kevlar/Epoxy COPV

We analyze the potential for liner buckling in a 40-in Kevlar49/epoxy overwrapped spherical pressure vessel (COPV) due to long, local depressions or valleys in the titanium liner, which appeared after proof testing (autofrettage). We begin by presenting the geometric characteristics of approximately 20 mil (0.02 in.) deep depressions measured by laser profilometry in several vessels. While such depths were more typical, depths of more than 40 mils (0.02 in.) were seen near the equator in one particular vessel. Such depressions are largely the result of overlap of the edges of overwrap bands (with rectangular cross-section prepreg tows) from the first or second wrap patterns particularly where they start and end. We then discuss the physical mechanisms of formation of the depressions during the autofrettage process in terms of uneven void compaction in the overwrap around the tow overlap lines and the resulting 10-fold increase in through-thickness stiffness of the overwrap. We consider the effects of liner plastic yielding mechanisms in the liner on residual bending moments and interface pressures with the overwrap both at the peak proof pressure (approx.6500 psi) and when reducing the pressure to 0 psi. During depressurization the Bauschinger phenomenon becomes very important whereby extensive yielding in tension reduces the magnitude of the yield threshold in compression by 30 to 40%, compared to the virgin annealed state of the liner titanium. In the absence of a depression, the liner is elastically stable in compression even at liner overwrap interface pressures nominally 6 times the approx. 1000 psi interface pressure that exists at 0 psi. Using a model based on a plate-on-an-elastic-foundation, we develop an extensive analysis of the possible destabilizing effects of a frozen-in valley. The analysis treats the modifying effects of the residual bending moments and interface pressures remaining after the proof hold as well as the Bauschinger effect on the compressive yield threshold. The key result is that depression depths of up to 40 mils can be tolerated, but above 40 mils, the Bauschinger effect drives destabilization, and buckling becomes increasingly likely depending on the details of depression formation during autofrettage. It is almost certain that destabilization and buckling will occur for depression depths beyond 55 mils. The main equations and formulas for treating the various phases of depression development and potential buckling, are only briefly outlined in the paper, but are available from the authors.

Phoenix, S. Leigh↗

NASA NTRS2009

A Finite Element Theory for Predicting the Attenuation of Extended-Reacting Liners

A non-modal finite element theory for predicting the attenuation of an extended-reacting liner containing a porous facesheet and located in a no-flow duct is presented. The mathematical approach is to solve separate wave equations in the liner and duct airway and to couple these two solutions by invoking kinematic constraints at the facesheet that are consistent with a continuum theory of fluid motion. Given the liner intrinsic properties, a weak Galerkin finite element formulation with cubic polynomial basis functions is used as the basis for generating a discrete system of acoustic equations that are solved to obtain the coupled acoustic field. A state-of-the-art, asymmetric, parallel, sparse equation solver is implemented that allows tens of thousands of grid points to be analyzed. A grid refinement study is presented to show that the predicted attenuation converges. Excellent comparison of the numerically predicted attenuation to that of a mode theory (using a Haynes 25 metal foam liner) is used to validate the computational approach. Simulations are also presented for fifteen porous plate, extended-reacting liners. The construction of some of the porous plate liners suggest that they should behave as resonant liners while the construction of others suggest that they should behave as broadband attenuators. In each case the finite element theory is observed to predict the proper attenuation trend.

Watson, W. R.↗

NASA NTRS2014

High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner For Advanced Rocket Engines

Advanced high thermal conductivity materials research conducted at NASA Marshall Space Flight Center (MSFC) with state of the art combustion chamber liner material NARloy-Z showed that its thermal conductivity can be increased significantly by adding diamond particles and sintering it at high temperatures. For instance, NARloy-Z containing 40 vol. percent diamond particles, sintered at 975C to full density by using the Field assisted Sintering Technology (FAST) showed 69 percent higher thermal conductivity than baseline NARloy-Z. Furthermore, NARloy-Z-40vol. percent D is 30 percent lighter than NARloy-Z and hence the density normalized thermal conductivity is 140 percent better. These attributes will improve the performance and life of the advanced rocket engines significantly. By one estimate, increased thermal conductivity will directly translate into increased turbopump power up to 2X and increased chamber pressure for improved thrust and ISP, resulting in an expected 20 percent improvement in engine performance. Follow on research is now being conducted to demonstrate the benefits of this high thermal conductivity NARloy-Z-D composite for combustion chamber liner applications in advanced rocket engines. The work consists of a) Optimizing the chemistry and heat treatment for NARloy-Z-D composite, b) Developing design properties (thermal and mechanical) for the optimized NARloy-Z-D, c) Fabrication of net shape subscale combustion chamber liner, and d) Hot fire testing of the liner for performance. FAST is used for consolidating and sintering NARlo-Z-D. The subscale cylindrical liner with built in channels for coolant flow is also fabricated near net shape using the FAST process. The liner will be assembled into a test rig and hot fire tested in the MSFC test facility to determine performance. This paper describes the development of this novel high thermal conductivity NARloy-Z-D composite material, and the advanced net shape technology to fabricate the combustion chamber liner. Properties of optimized NARloy-Z-D composite material will also be presented.

Bhat, Biliyar N.↗

NASA NTRS2015

High Thermal Conductivity NARloy-Z-Diamond Composite Liner for Advanced Rocket Engines

NARloy-Z (Cu-3Ag-0.5Zr) alloy is state-of-the-art combustion chamber liner material used in liquid propulsion engines such as the RS-68 and RS-25. The performance of future liquid propulsion systems can be improved significantly by increasing the heat transfer through the combustion chamber liner. Prior work1 done at NASA Marshall Space Flight Center (MSFC) has shown that the thermal conductivity of NARloy-Z alloy can be improved significantly by embedding high thermal conductivity diamond particles in the alloy matrix to form NARloy-Z-diamond composite (fig. 1). NARloy-Z-diamond composite containing 40vol% diamond showed 69% higher thermal conductivity than NARloy-Z. It is 24% lighter than NARloy-Z and hence the density normalized thermal conductivity is 120% better. These attributes will improve the performance and life of the advanced rocket engines significantly. The research work consists of (a) developing design properties (thermal and mechanical) of NARloy-Z-D composite, (b) fabrication of net shape subscale combustion chamber liner, and (c) hot-fire testing of the liner to test performance. Initially, NARloy-Z-D composite slabs were made using the Field Assisted Sintering Technology (FAST) for the purpose of determining design properties. In the next step, a cylindrical shape was fabricated to demonstrate feasibility (fig. 3). The liner consists of six cylinders which are sintered separately and then stacked and diffusion bonded to make the liner (fig. 4). The liner will be heat treated, finish-machined, and assembled into a combustion chamber and hot-fire tested in the MSFC test facility (TF 115) to determine perform.

Bhat, Biliyar↗

NASA NTRS2016

Further Development and Assessment of a Broadband Liner Optimization Process

The utilization of advanced fan designs (including higher bypass ratios) and shorter engine nacelles has highlighted a need for increased fan noise reduction over a broader frequency range. Thus, improved broadband liner designs must account for these constraints and, where applicable, take advantage of advanced manufacturing techniques that have opened new possibilities for novel configurations. This work focuses on the use of an established broadband acoustic liner optimization process to design a variable-depth, multi-degree of freedom liner for a high speed fan. Specifically, in-duct attenuation predictions with a statistical source model are used to obtain optimum impedance spectra over the conditions of interest. The predicted optimum impedance information is then used with acoustic liner modeling tools to design a liner aimed at producing impedance spectra that most closely match the predicted optimum values. The multi-degree of freedom design is carried through design, fabrication, and testing. In-duct attenuation predictions compare well with measured data and the multi-degree of freedom liner is shown to outperform a more conventional liner over a range of flow conditions. These promising results provide further confidence in the design tool, as well as the enhancements made to the overall design process.

Nark, Douglas M.↗

NASA NTRS2017

Experimental Evaluation of Acoustic Engine Liner Models Developed with COMSOL Multiphysics

Accurate modeling tools are needed to design new engine liners capable of reducing aircraft noise. The purpose of this study is to determine if a commercially-available finite element package, COMSOL Multiphysics, can be used to accurately model a range of different acoustic engine liner designs, and in the process, collect and document a benchmark dataset that can be used in both current and future code evaluation activities. To achieve these goals, a variety of liner samples, ranging from conventional perforate-over-honeycomb to extended-reaction designs, were installed in one wall of the grazing flow impedance tube at the NASA Langley Research Center. The liners were exposed to high sound pressure levels and grazing flow, and the effect of the liner on the sound field in the flow duct was measured. These measurements were then compared with predictions. While this report only includes comparisons for a subset of the configurations, the full database of all measurements and predictions is available in electronic format upon request. The results demonstrate that both conventional perforate-over-honeycomb and extended-reaction liners can be accurately modeled using COMSOL. Therefore, this modeling tool can be used with confidence to supplement the current suite of acoustic propagation codes, and ultimately develop new acoustic engine liners designed to reduce aircraft noise.

Schiller, Noah H.↗

NASA NTRS2018

Broadband Inlet Liner Design for the DGEN Aero-Propulsion Research Turbofan

The utilization of advanced fan designs (including higher bypass ratios) and shorter engine nacelles has highlighted a need for increased fan noise reduction over a broad frequency range. With these observations in mind, an acoustic liner optimization process has been developed to achieve improved broadband liner designs. A series of advanced liner design studies at increasing technology readiness levels has been conducted as the overall optimization methodology has been enhanced. In this work, further validation was pursued through the fabrication and testing of two liner designs for the NASA Glenn DGEN Aero-propulsion Research Turbofan. Specifically, single and three layer liners were designed, fabricated, and tested. Analysis of the predicted attenuation results showed them to generally match expected trends for the conditions considered. The effects of source distribution on predicted directivity were also illustrated through the flexibility of a statistical source model. As part of the analysis, the overall design and evaluation capability was extended such that external observer locations may be included in the optimization process. This enhancement will provide a much wider design space for the development of advanced broadband liners. These preliminary results provide further confidence in the design tools and enhancements made to the overall liner design process.

Nark, Douglas M.↗

NASA NTRS2018

Smeared Impedence Model for Variable Depth Liners

Noise from modern aircraft engines has a significant broadband component, which has motivated the need for broadband acoustic engine liners. A promising broadband design, called a variable depth liner, is composed of groups of resonators tuned for different frequencies. The accuracy of commonly used smeared impedance models, however, has not been thoroughly assessed for this type of liner. Therefore, the purpose of this study is to assess, and if necessary develop, semi-analytical impedance models for variable depth designs. The impedance prediction is complicated by the fact that the radiation loading on individual resonators within the array can be different. While the radiation loading can be neglected on conventional engine liners that consist of a dense array of uniform resonators, the same is not true for variable depth liners. To better understand and model this effect, nine liner samples are tested in the NASA Langley normal incidence tube. Comparisons of predicted and measured data for relatively simple non-uniform samples confirm that the radiation loading can be approximated using mass end correction terms. Semi-analytical impedance models that incorporate the proposed end corrections provide favorable comparisons with measured impedance spectra for variable depth liner samples.

Schiller, Noah H.↗

NASA NTRS2019

Overview of Liner Activities in Support of the International Forum for Aviation Research

This paper provides an overview of liner research being conducted by members of the International Forum for Aviation Research (IFAR). The IFAR consists of representatives from a number of national research labs and is established to enable information exchange on aviation research activities. NASA has provided three challenges that explore different aspects of acoustic liner research, and will compile the results from each of the partners into a common database when the challenges are completed. The goal of the first challenge is to compare experimental methods applied at different national labs for acoustic liner evaluation, and to compare impedance eduction methodologies for uniform liners. The second challenge is to evaluate the ability of 3D propagation codes to predict the effects of spanwise variable-impedance liners on the acoustic pressure field. The third challenge is to explore different approaches to simultaneously educe the impedances for each zone of a three-zone liner. Each challenge is intended to be conducted as a blind test. Thus, only representative results achieved by the NASA Liner Physics Team for each of the three challenges are presented herein. When the results from all participants are available, the compiled results are intended to be provided in future reports.

Jones, Michael G.↗

NASA NTRSDate not supplied

Bypass Duct Acoustic Liner Design With and Without Bifurcation Effects

The growth in air traffic and the commitment to sustainable aviation continue to provide new challenges to reducing aircraft noise levels. Acoustic liner design methodologies must therefore provide the capability to efficiently predict the acoustic benefits of novel liner configurations within complex aircraft nacelle geometries. With these observations in mind, a broadband acoustic liner optimization process has been developed and assessed through a series of design and experimental studies at increasing technology readiness levels. This work applies the design process to the aft-fan noise component and explores the effects of bypass duct bifurcations (e.g., the pylon and lower bifurcation). In addition to this new application, the design study is expanded to include the use of a commercially available duct propagation code. Despite the different general workflow for the two propagation codes, consistent optimized impedance spectra and in-duct attenuation predictions were obtained for several acoustic treatment options. The preliminary results are promising, and this work increases confidence in the enhanced broadband liner design methodology and lays the groundwork for complimentary use of the codes in future studies. The potential benefits of acoustic treatment on the upper and lower bifurcations are also demonstrated. The knowledge gained through this preliminary stage of the liner design process will be used to guide the identification of candidate liner designs for a proposed static engine test within the next year.

Acoustic Liner Design↗

NASA NTRSDate not supplied

Bypass Duct Acoustic Liner Design with and without Bifurcation Effects

Acoustic Liner Design↗

NASA NTRS2022

Acoustic Modeling of Novel Over-The-Rotor Acoustic Liner Concepts Using COMSOL Multiphysics Simulation Software

This paper presents simulation predictions of novel over-the-rotor acoustic liner configurations compared with experimental data. This is a follow on to the investigation on the effect of grazing flow on grooved over-the-rotor casing treatments. The purpose of this modeling investigation stems from the determination that traditional liner modeling techniques are inadequate for nontraditional internal liner cavity geometries. A series of these expansion chamber type liner design concepts were previously developed by Glenn Research Center and tested using the Langley Research Center Normal Incidence Tube. The measured normalized impedance and absorption coefficient is compared with that obtained from the COMSOL Multiphysics® simulation. Additionally, using a parametric case study, another series of simulations were conducted to determine what additional benefits, if any, this genre of liner has to offer the acoustics community. A total of 53 permutations of this concept was investigated. The results indicate that with longer internal fins, the resonance is sifted to lower frequencies.

Acoustics↗

DOE OSTI2023

Temperature Rise on Liner Surfaces of Fuel Cell Electric Vehicle Tanks during Fueling Process

Herein, the temperature of the inner tank walls, or plastic liners, of composite pressure tanks in fuel cell electric vehicles during fueling using three‐dimensional computational fluid dynamics (CFD) models is evaluated. The liner materials are limited to 85.0 °C to prevent thermal stress causing material failure that would result in a hydrogen leak. Therefore, the temperature of hydrogen gas must be limited to below 85.0 °C during the fueling process as dictated by the current fueling protocol. However, there are limited experimental or simulation data confirming that the temperature changes do not exceed the threshold. Herein, the liner temperatures with CFD tank models for two sizes of type IV tanks representative of the upper and lower system bounds that are close to the SAE J2601 fueling protocol (36.0 and 244.0 L) are evaluated. First, each model's reliability is validated with experimental data and then analyzed, and the data are used to evaluate the maximum hydrogen and liner temperatures under real‐world fueling conditions. The evaluation shows that the maximum liner surface temperature of each tank model is at least 7 °C lower than that of the hydrogen. Additionally, there is at least 12 °C difference found between the upper limit and actual liner temperatures.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2023

Effects of Layer Spacing for a Multilayered Facesheet Acoustic Liner

A single degree-of-freedom acoustic liner, a perforate facesheet over honeycomb core, is modified to have a facesheet comprised of three layers. The top and bottom perforate layers have the same dimensions with aligned perforations while the middle layer perforate can be longitudinally shifted up to 0.075 inches to change the effective porosity of the facesheet. These configurations range in porosity from 100% open down to 10% open in addition to two closed configurations (0% porosity). Gaps are introduced between the facesheet layers ranging from no gap to 0.016 inches. These configurations are tested in the NASA Langley Grazing Flow Impedance Tube to determine their acoustic impedance spectra. Introduction of a gap affects the acoustic impedance of the liner where the resonant frequency of the liners decreases with increased gap thickness for liners with an open area ratio above 25% but increases with gap thickness for liners with an open area ratio below 25%. Additionally, it is observed that increasing the gap height results in a reduction of the effect of porosity on acoustic impedance. The results show that the presence of such gaps can have a significant effect on liner impedance especially as porosity decreases.

acoustic liners↗

NASA NTRSDate not supplied

Microstructure Controlled Multi-Layer Porous Material Liner Tested On The Advanced Noise Control Fan

A novel concept of multilayer micro structurally controlled noise mitigation porous material was developed and experimentally validated in the laboratory by normal incidence impedance test. Extensive parametric studies were made to understand various parameters that influence acoustic absorption and transmission loss based on the test specimen size, particle size, porosity, pore size, and its distribution through the thickness. The results were reported in many publications. This work was focused on applying the concept and assessing the validity of the technology to aircraft turbomachine engines. The NASA Glenn Research Center’s Advanced Noise Control Fan (ANCF) low-speed test rig was selected. The liner insert required a 4-ft internal diameter cylinder with a 2-inch thick and 9-inch axial length. The liner was fabricated in eight segments and assembled in an aluminum test rig. The liner was tested for both tonal and broadband noise at the Notre Dame Turbomachinery Lab White Field test facility, where the ANCF is located. The study concludes that: Microstructurally controlled porous material is very effective in dissipating the sound energy; the liner is effective for tonal noise (2 to 13 dB reduction in noise levels) that constitutes the major part of the overall fan noise, especially the blade passing frequency which is generally the dominating component; Also, the liner is effective for broadband noise with reductions in sound pressure level of about 3 dB for the shaft order greater than 20. The proposed two-layer liner model demonstrated the validity of the concept. More studies are required to optimize the design.

Liner↗

NASA NTRSDate not supplied

Acoustic Liner Drag: Measurement Uncertainty Reduction and Application to Novel Perforate Geometries

In addition to developing acoustic liner concepts and characterizing their performance, the NASA Langley Liner Physics Team has investigated issues related to liner drag. A method to quantify relative drag of liner configurations was developed and employed to understand the effects of various liner features. It was observed that perforate shape could have a marked effect on the measured liner drag and led to the discovery of a low-drag geometry that cut the drag penalty between a perforate and a smooth wall by approximately 50%. Investigations of novel perforates to further reduce drag were stymied by measurement uncertainty that prevented further resolution of drag differences between configurations. The current study details efforts to understand the causes of this uncertainty and describe changes made to testing methods to reduce it. Previously evaluated perforates were retested with these improvements in the NASA Langley Grazing Flow Impedance Tube to determine their relative drag at a flow speed of Mach 0.5 without acoustic excitation. Their performance was compared to the previously identified low-drag geometry to see if further drag reductions could be realized.

drag↗

NASA NTRSDate not supplied

Acoustic Liner Drag: Measurement Uncertainty Reduction and Application to Novel Perforate Geometries

drag↗

DOE OSTI2021

Fusion gain from cylindrical liner-driven implosions of field reversed configurations

MagLIF experiments [M.R. Gomez et al., Phys. Plasmas 22, 056306 (2015)] on Z have demonstrated the basic principles of Magneto-Inertial Fusion (MIF) for wall confined plasmas. Other MIF schemes have been proposed based on the liner implosion of closed field magnetically confined plasmas such as Field Reversed Configurations (FRCs) [T. P. Intrator et al., Phys. Plasmas 15, 042505 (2008)]. We present a semi-analytical model of liner driven FRC implosions that predicts the fusion gain of such systems. The model predicts a fusion gain near unity for an FRC imploded by a liner driven by the Z Machine. We show that FRCs could be formed and imploded at the Z facility using the AutoMag liner concept [S. A. Slutz et al., Phys. Plasmas 24, 012704 (2017)]. Furthermore, an initial bias magnetic field can be supplied by the external magnets used in MagLIF experiments. The reverse field is then supplied by an AutoMag liner, which has helical conducting paths imbedded in an insulating substance. Experiments [Shipley et al., Phys. Plasmas 26, 052705 (2019)] have demonstrated that AutoMag can generate magnetic fields greater than 30 Tesla inside of the liner. We have performed 2D Radiation MHD simulations of the formation and implosion of an FRC, which are in good agreement with the analytical model. The FRC formation process could be studied on small pulsed power machines delivering about 1 MA.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗