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All sourcesNASA NTRSDOE OSTI
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 NTRS1981

Effects of blade-vane ratio and rotor-stator spacing of fan noise with forward velocity

A research fan stage was acoustically tested in an anechoic wind tunnel with a 41 m/sec tunnel flow. Two stator vane numbers giving cut-on and cut-off conditions were tested at three rotor-stator spacings ranging from about 0.5 to 2.0 rotor chords. These two stators were designed for similar aerodynamic performance. Hot film anemometer turbulence measurements were made at the leading edge of the stator for each spacing. The cut-off criterion strongly controlled the fundamental tone level at all spacings. The trends with spacing of the wake defect upwash component at the stator tip showed good agreement with the corresponding cut-on acoustic tone levels.

Woodward, R. P.↗
NASA NTRS1981

Effects of blade-vane ratio and rotor-stator spacing on fan noise with forward velocity

A research fan stage is acoustically tested in an anechoic wind tunnel with a 41 m/sec tunnel flow. Two stator vane numbers giving cut-on and cut-off conditions are tested at three rotor stator spacings ranging from 0.5 to 2.0 rotor chords. Hot-film anemometer turbulence measurements are made at the leading edge of the stator for each spacing, and a crossed film anemometer is radially transversed to define streamwise and upwash characteristics of the rotor blade wakes. Trends in the acoustic results are observed in the front and aft quadrants at 80% design fan speed. Aft quadrant results demonstrate a fundamental tone 9 dB lower for the 25 vane stator than for the 11 vane stator, while overtone levels are 3 dB higher. The cut-off criterion strongly controls fundamental tone level at all spacings, and spacing trends of the wake-defect upwash component show good agreement with corresponding cut-on acoustic tone levels.

Woodward, R. P.↗
NASA NTRS1976

Aerodynamic characteristics of a vane flow angularity sensor system capable of measuring flight path accelerations for the Mach number range from 0.40 to 2.54

The aerodynamic characteristics of the angle of attack vane and the angle of sideslip vane are summarized. The test conditions ranged in free stream Mach number from 0.40 to 2.54, in angle of attack from -2 deg to 22 deg, in angle of sideslip from -2 deg to 12 deg, and in Reynolds number from 590,000 per meter to 1.8 million per meter. The results of the wind tunnel investigation are compared with results obtained with similar vane configurations. Comparisons with a NACA vane configuration are also made. In addition, wind tunnel-derived upwash for the test installation is compared with analytical predictions.

Sakamoto, G. M.↗
NASA NTRS2023

Acoustic Results of Over the Rotor and Soft Vane Treatments on the Source Diagnostic Test Model in the NASA Glenn Research Center 9- by 15-foot Low-Speed Wind Tunnel

Two novel fan noise reduction concepts were tested using the Source Diagnostic Test fan stage model in the NASA Glenn 9x15 Low Speed Wind Tunnel. One, referred to as over the rotor treatment, consisted of a number of different casing treatments some of which contained acoustic treatment. The other, known as soft vane, consisted of fan exit guide vanes whose interior volume contained acoustic treatment that was exposed to the vane suction side surface through a perforate.

Aeroacoustics↗
NASA NTRS1973

Bucket rotor wind-driven generator

As compared with the ordinary propeller type rotor, the bucket rotor is limited in rotational speed since the tip rotor speed can never exceed the wind speed. However, it does not present the blade fatigue problem that the ordinary rotor has, and it perhaps causes less sight pollution. The deflector vanes also provide a venturi passage to capture greater wind flow. The bucket rotors can be strung together end-to-end up to thousands of feet long to produce large amounts of power.

Chang, H. H.↗
NASA NTRS2010

Optimal Flow Control Design

In support of the Blended-Wing-Body aircraft concept, a new flow control hybrid vane/jet design has been developed for use in a boundary-layer-ingesting (BLI) offset inlet in transonic flows. This inlet flow control is designed to minimize the engine fan-face distortion levels and the first five Fourier harmonic half amplitudes while maximizing the inlet pressure recovery. This concept represents a potentially enabling technology for quieter and more environmentally friendly transport aircraft. An optimum vane design was found by minimizing the engine fan-face distortion, DC60, and the first five Fourier harmonic half amplitudes, while maximizing the total pressure recovery. The optimal vane design was then used in a BLI inlet wind tunnel experiment at NASA Langley's 0.3-meter transonic cryogenic tunnel. The experimental results demonstrated an 80-percent decrease in DPCPavg, the reduction in the circumferential distortion levels, at an inlet mass flow rate corresponding to the middle of the operational range at the cruise condition. Even though the vanes were designed at a single inlet mass flow rate, they performed very well over the entire inlet mass flow range tested in the wind tunnel experiment with the addition of a small amount of jet flow control. While the circumferential distortion was decreased, the radial distortion on the outer rings at the aerodynamic interface plane (AIP) increased. This was a result of the large boundary layer being distributed from the bottom of the AIP in the baseline case to the outer edges of the AIP when using the vortex generator (VG) vane flow control. Experimental results, as already mentioned, showed an 80-percent reduction of DPCPavg, the circumferential distortion level at the engine fan-face. The hybrid approach leverages strengths of vane and jet flow control devices, increasing inlet performance over a broader operational range with significant reduction in mass flow requirements. Minimal distortion level requirements are met using vanes alone, avoiding engine stall and increasing robustness of this hybrid inlet flow control approach. This design applies to aerospace applications needing flush-mounted boundary-layer-ingesting inlets.

Allan, Brian↗
NASA NTRS1987

A three-dimensional dual potential procedure for inlets and indraft wind tunnels

A dual potential decomposition of the velocity field into a scalar and a vector potential function is extended to three dimensions and used in the finite-difference simulation of steady three-dimensional inviscid rotational flow through ducts and inlets. The procedure has been used to simulate the flow through the 80- by 120-Foot Wind Tunnel at NASA Ames Research Center. Vanes and screens located at the entrance of the inlet are modeled using actuator disk theory. The numerical predictions are in good agreement with experimental data.

Rao, K. V.↗
NASA NTRS1992

Separation control on high Reynolds number multi-element airfoils

Small surface-mounted vortex generators were investigated as means for the control of a boundary-layer separation on a 2D single-flap three-element high-lift system at near-flight Reynolds numbers and in landing configurations. Wind-tunnel results obtained for small vane-type vortex generators mounted on a multielement airfoil showed that vortex generators as small as 0.18 percent of total chord can effectively reduce or eliminate boundary-layer separation on the flap at approach conditions. It was found that both the outerrotating and the corotating streamwise vortices were effective in reducing flow separation.

Lin, John C.↗
NASA NTRSDate not supplied

Inlet Vortex Generator Design for the X-59 Low Boom Flight Demonstrator

An array of vortex generators was designed for the X-59 Low Boom Flight Demonstrator aircraft inlet. Prior to the a High Speed Inlet Distortion Test, concern regarding potentially high measurements of steady state or dynamic distortion prompted an effort to examine the use of passive flow control to reduce distortion levels. Design of experiments methodology was used to develop two matrices of vortex generators placed inside the inlet serpentine duct and upstream of the inlet on the compression surface, varying on several geometric parameters. Reynolds-Averaged Navier-Stokes simulations were performed using the FUN3D flow solver at Mach 1.45 to analyze the impact of each configuration on total pressure recovery, circumferential distortion, and radial distortion. Results from simulations of the baseline aircraft are compared with data acquired in the NASA Glenn Research Center’s 8- by 6-foot Supersonic Wind Tunnel. A vortex generator configuration with vanes placed upstream of the inlet terminal shock was shown to significantly increase total pressure recovery and decrease circumferential distortion with no penalty to radial distortion levels. Inlet mass flow sweeps at Mach 1.45, 0.6, and 0.3 indicated no detrimental effects from the vanes at off-design conditions.

Vortex generators↗
NASA NTRS1987

Effects of the installation and operation of jet-exhaust yaw vanes on the longitudinal and lateral-directional characteristics of the F-14 airplane

A wind tunnel investigation was conducted in the Langley 16-Foot Transonic Tunnel to determine the effects of the installation and use of jet exhaust yaw vanes on the longitudinal and lateral-directional characteristics of the F-14 aircraft. The model was tested at Mach numbers from 0.70 to 1.25 at angles of attack from 0 deg to 4.3 deg. Compressed air was used to simulate nozzle exhaust flow from jet off up to a nozzle pressure ratio of 8. The results of the investigation show that the yaw vanes can augment the rudders to provide directional control, but further investigation will be necessary to optimize the deflection schedule associated with the various nozzle power settings.

Reubush, David E.↗
NASA NTRS1978

An anemometer for measuring velocities on the .25 to 4.25 M/sec range

A vane type anemometer was developed as a secondary standard for the on site calibration of wind velocity sensors. The instrument outputs an electrical pulse for each interruption of a light source by an eight vane fan. The pulse rate is proportional to the fan's angular speed and linearly related to wind velocity over the range 0.25 to 4.27 m/sec.

Carpini, T. D.↗
NASA NTRS1977

Lagrangian drifter design for the determination of surface currents by remote sensing

In estuaries, the interaction of wind, tidal current, and mixing of fresh and saline water produces a variable depth profile of current, with foam lines and convergence zones between water types. Careful measurement of surface currents via Lagrangian drifters requires a drifter design appropriate to both the depth of current to be measured and the tide and wind conditions of interest. The use of remote sensing to track drifters contributes additional constraints on drifter design. Several designs of biodegradable drifters which emit uranine dye plumes, resolvable in aerial imagery to 1:60,000 scale, were tested for wind drag in field conditions against data from calibrated current meters. A 20 cm-vaned wooden drifter and a window shade drifter set to 1.5 m depth had negligible wind drag in winds to 8 m/sec. Prediction of oil slick trajectories using surface current data and a wind factor should be approached cautiously, as surface current data may be wind-contaminated, while the usual 3.5% wind factor is appropriate only for currents measured at depth.

Gordon, H. H.↗
NASA NTRS2005

An Analysis of Peak Wind Speed Data from Collocated Mechanical and Ultrasonic Anemometers

This study focuses on a comparison of peak wind speeds reported by mechanical and ultrasonic anemometers at Cape Canaveral Air Force Station and Kennedy Space Center (CCAFS/KSC) on the east central coast of Florida and Vandenberg Air Force Base (VAFB) on the central coast of California. The legacy mechanical wind instruments on CCAFS/KSC and VAFB weather towers are being changed from propeller-and-vane (CCAFS/KSC) and cup-and-vane (VAFB) sensors to ultrasonic sensors under the Range Standardization and Automation (RSA) program. The wind tower networks on KSC/CCAFS and VAFB have 41 and 27 towers, respectively. Launch Weather Officers, forecasters, and Range Safety analysts at both locations need to understand the performance of the new wind sensors for a myriad of reasons that include weather warnings, watches, advisories, special ground processing operations, launch pad exposure forecasts, user Launch Commit Criteria (LCC) forecasts and evaluations, and toxic dispersion support. The Legacy sensors measure wind speed and direction mechanically. The ultrasonic RSA sensors have no moving parts. Ultrasonic sensors were originally developed to measure very light winds (Lewis and Dover 2004). The technology has evolved and now ultrasonic sensors provide reliable wind data over a broad range of wind speeds. However, because ultrasonic sensors respond more quickly than mechanical sensors to rapid fluctuations in speed, characteristic of gusty wind conditions, comparisons of data from the two sensor types have shown differences in the statistics of peak wind speeds (Lewis and Dover 2004). The 45th Weather Squadron (45 WS) and the 30 WS requested the Applied Meteorology Unit (AMU) to compare data from RSA and Legacy sensors to determine if there are significant differences in peak wind speed information from the two systems.

Short, David A.↗
NASA NTRS2003

Three-Dimensional Venturi Sensor for Measuring Extreme Winds

A three-dimensional (3D) Venturi sensor is being developed as a compact, rugged means of measuring wind vectors having magnitudes of as much as 300 mph (134 m/s). This sensor also incorporates auxiliary sensors for measuring temperature from -40 to +120 F (-40 to +49 C), relative humidity from 0 to 100 percent, and atmospheric pressure from 846 to 1,084 millibar (85 to 108 kPa). Conventional cup-and-vane anemometers are highly susceptible to damage by both high wind forces and debris, due to their moving parts and large profiles. In addition, they exhibit slow recovery times contributing to an inaccurately high average-speed reading. Ultrasonic and hot-wire anemometers overcome some of the disadvantages of the cup and-vane anemometers, but they have other disadvantageous features, including limited dynamic range and susceptibility to errors caused by external acoustic noise and rain. In contrast, the novel 3D Venturi sensor is less vulnerable to wind damage because of its smaller profile and ruggedness. Since the sensor has no moving parts, it provides increased reliability and lower maintenance costs. It has faster response and recovery times to changing wind conditions than traditional systems. In addition, it offers wide dynamic range and is expected to be relatively insensitive to rain and acoustic energy. The Venturi effect in this sensor is achieved by the mirrored double-inflection curve, which is then rotated 360 to create the desired detection surfaces. The curve is optimized to provide a good balance of pressure difference between sensor ports and overall maximum fluid velocity while in the shape. Four posts are used to separate the two shapes, and their size and location were chosen to minimize effects on the pressure measurements. The 3D Venturi sensor has smart software algorithms to map the wind pressure exerted on the surfaces of the design. Using Bernoulli's equation, the speed of the wind is calculated from the differences among the pressure readings at the various ports. The direction of the wind is calculated from the spatial distribution and magnitude of the pressure readings. All of the pressure port sizes and locations have been optimized to minimize measurement errors and to reside in areas demonstrating a stable pressure reading proportional to the velocity range.

Zysko, Jan A.↗
NASA NTRS1972

Oxidation resistant porous material for transpiration cooled vanes

Porous metal sheet with controlled permeability was made by space winding and diffusion bonding fine wire. Two iron-chromium-aluminum alloys and three-chromium alloys were used: GE 1541 (Fe-Cr-Al-Y), H 875 (Fe-Cr-Al-Si), TD Ni Cr, DH 245 (Ni-Cr-Al-Si) and DH 242 (Ni-Cr-Si-Cb). GE 1541 and H 875 were shown in initial tests to have greater oxidation resistance than the other candidate alloys and were therefore tested more extensively. These two materials were cyclic furnace oxidation tested in air at 1800 and 2000 F for accumulated exposure times of 4, 16, 64, 100, 200, 300, 400, 500, and and 600 hours. Oxidation weight gain, permeability change and mechanical properties were determined after exposure. Metallographic examination was performed to determine effects of exposure on the porous metal and electron beam weld joints of porous sheet to IN 100 strut material. Hundred hour stress rupture life and tensile tests were performed at 1800 F. Both alloys had excellent oxidation resistance and retention of mechanical properties and appear suitable for use as transpiration cooling materials in high temperature gas turbine engines.

Madsen, P.↗