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NASA NTRS2015

Progress in Open Rotor Research: A U.S. Perspective

In response to the 1970s oil crisis, NASA created the Advanced Turboprop Project (ATP) to mature technologies for high-speed propellers to enable large reductions in fuel burn relative to turbofan engines of that era. Both single rotation and contra- rotation concepts were designed and tested in ground based facilities as well as flight. Some novel concepts/configurations were proposed as part of the effort. The high-speed propeller concepts did provide fuel burn savings, albeit with some acoustics and structural challenges to overcome. When fuel prices fell, the business case for radical new engine configurations collapsed and the research emphasis returned to high bypass ducted configurations. With rising oil prices and increased environmental concerns there is renewed interest in high-speed propeller based engine architectures. Contemporary analysis tools for aerodynamics and aeroacoustics have enabled a new era of blade designs that have both high efficiency and lower noise characteristics. A recent series of tests in the U.S. have characterized the aerodynamic performance and noise from these modern contra-rotating propeller designs. Additionally the installation and noise shielding aspects for conventional airframes and blended wing bodies have been studied. Historical estimates of 'propfan' performance have relied on legacy propeller performance and acoustics data. Current system studies make use of the modern propeller data and higher fidelity installation effects data to estimate the performance of a contemporary aircraft system. Contemporary designs have demonstrated high net efficiency, approximately 86%, at 0.78 Mach, and low noise, greater than 15 EPNdB cumulative margin to Chapter 4 when analyzed on a NASA derived aircraft/mission. This paper presents the current state of high-speed propeller/open rotor research within the U.S. from an overall viewpoint of the various efforts ongoing. The remaining technical challenges to a production engine include propulsion airframe integration, acoustic sensitivity to aircraft weight and certification issues.

Aerodynamics↗

NASA NTRS1975

Summary of model VTOL lift fan tests conducted at NASA Lewis Research Center

The purpose of the tests was to obtain overall performance and influencing factors as well as detailed measurements of the internal flow characteristics. The first experiment consisted of crossflow tests of a 15-inch diameter fan installed in a two-dimensional wing. Tests were run with and without exit louvers over a range of tunnel speeds, fan speeds, and wing angle of attack. The wing was used for a study of installation effects on lift fan performance. The model tested consisted of three 5.5-inch diameter tip-turbine driven model VTOL lift fans mounted chord-wise in the two-dimensional wing to simulate a pod-type array. Several inlet and exit cover door configurations and an adjacent fuselage panel were tested. For the third program, a pod was attached to the wing, and an investigation was conducted of the effect of design tip speed on the aerodynamic performance and noise of a 15-inch diameter lift fan-in-pod under static and crossflow conditions. Three single VTOL lift fan stages were designed for the same overall total pressure ratio but at three different rotor tip speeds.

Diedrich, J. H.↗

NASA NTRS2000

Development and Demonstration of Active Noise Control Concepts

This report details design methods for and feasibility of an Active Noise Control (ANC) system using flush-wall-mounted sensors and actuators to reduce turbofan engine rotor-stator interaction noise. ANC concepts capable of suppressing discrete-tone spinning modes containing several cut-on radial mode were identified, developed analytically, and evaluated. Separate ANC systems that suppressed at least three radial modes in a cylindrical inlet duct and three radial modes in an exhaust annulus were developed. These designs resulted in inlet duct and exhaust duct tests that were performed at NASA on the 4-ft ANC Fan in the NASA Glenn AAPL facility. Effective suppression of 2-BPF spinning mode m = 2 tone noise was achieved over a range of fan speeds 1800 to 2450 rpm, where up to 4 radials were present. In the inlet duct, up to 12 dB reduction was obtained for 3 radial modes, and up to 4 dB was obtained with 4 radial modes. In the exhaust duct, up to 15 dB PWL reduction was obtained with either two or three radial modes present. Thus, the ability to suppress multiple radial modes for tones in both the inlet and exhaust ducts has been successfully demonstrated. Implications of ANC system design requirements on installation and system integration issues for ANC systems capable of suppressing higher order radial mode content when applied to a 767 using twin CF6 engines were evaluated analytically. The analytical results indicated an ANC system must be part of an integrated design to be effective.

Kraft, R.↗

NASA NTRS2000

Modernization and Activation of the NASA Ames 11- by 11-Foot Transonic Wind Tunnel

The Unitary Plan Wind Tunnel (UPWT) was modernized to improve performance, capability, productivity, and reliability. Automation systems were installed in all three UPWT tunnel legs and the Auxiliaries facility. Major improvements were made to the four control rooms, model support systems, main drive motors, and main drive speed control. Pressure vessel repairs and refurbishment to the electrical distribution system were also completed. Significant changes were made to improve test section flow quality in the 11-by 11-Foot Transonic leg. After the completion of the construction phase of the project, acceptance and checkout testing was performed to demonstrate the capabilities of the modernized facility. A pneumatic test of the tunnel circuit was performed to verify the structural integrity of the pressure vessel before wind-on operations. Test section turbulence, flow angularity, and acoustic parameters were measured throughout the tunnel envelope to determine the effects of the tunnel flow quality improvements. The new control system processes were thoroughly checked during wind-off and wind-on operations. Manual subsystem modes and automated supervisory modes of tunnel operation were validated. The aerodynamic and structural performance of both the new composite compressor rotor blades and the old aluminum rotor blades was measured. The entire subsonic and supersonic envelope of the 11-by 11-Foot Transonic leg was defined up to the maximum total pressure.

Kmak, Frank J.↗

NASA NTRSDate not supplied

Coaxial Rotor CFD Validation and ML Surrogate Model Generation

A fixed-pitch speed-controlled coaxial rotor system was tested in the NASA Langley Transonic Dynamics Tunnel in September 2022. The rotors have a diameter of 1.35 meters and an inter-rotor spacing of 25% of the diameter. Though this test was focused on the NASA New Frontiers Dragonfly mission, the resulting dataset is relevant to a wide array of applications of multirotor vehicles, especially those using fixed-pitch variable-speed rotors. Most notably beyond Dragonfly, perhaps, is the application of coaxial rotor pair configurations for eVTOL and Urban Air Mobility (UAM) aircraft. This work provides a thorough CFD validation study quantifying coaxial rotor performance estimation with accuracy on order 5-10% using an efficient hybrid BEMT-URANS flow solver over a wide range of operating conditions. This accuracy was achieved using novel approaches for the construction of both the C81 airfoil performance lookup tables and the BEMT rotor model. These novel approaches are combined with advanced scripting to further accelerate the commercial off-the-shelf CFD solver on GPU accelerated machines. Finally, the development of machine learning surrogate models is presented to produce highly efficient and accurate rotor performance predictions for fixed-pitch variable-speed multirotor aircraft over the complete flight regime including scout, cruise, climb, descent, as well as limiting cases of vortex-ring and windmill-brake states.

Coaxial↗

NASA NTRS1975

Tests of laser metal removal for future flexible rotor balancing in engines

This paper describes recent developments in the flexible rotor balancing technology area, with particular emphasis on methods for the addition and removal of correction weights. The currently existing multiplane-multispeed balancing procedure permits one-step balancing of final shaft-bearing assemblies simultaneously in a number of planes and at a number of speeds. Temporary addition of trial weights to the rotor, and the addition or subtraction of permanent corrections, are presently performed manually in the balancing process. The addition of a computer-controlled laser device to the balancing system shows promise of eliminating direct operator contact with the rotor in the balancing process, and thus could provide a considerable increase in the precision level at a critical step in the procedure.

Tessarzik, J. M.↗

NASA NTRS1976

Preliminary simulation of an advanced, hingless rotor XV-15 tilt-rotor aircraft

The feasibility of the tilt-rotor concept was verified through investigation of the performance, stability and handling qualities of the XV-15 tilt rotor. The rotors were replaced by advanced-technology fiberglass/composite hingless rotors of larger diameter, combined with an advanced integrated fly-by-wire control system. A parametric simulation model of the HRXV-15 was developed, model was used to define acceptable preliminary ranges of primary and secondary control schedules as functions of the flight parameters, to evaluate performance, flying qualities and structural loads, and to have a Boeing-Vertol pilot conduct a simulated flight test evaluation of the aircraft.

Mcveigh, M. A.↗

NASA NTRS1980

Design and performance of compliant thrust bearing with spiral-groove membranes on resilient supports

Novel thrust bearings with spiral-groove flexible membranes mounted on resilient supports were designed and their performance demonstrated. Advantages of surface compliance were combined with the superior load-capacity of the spiral-groove geometry. Loads of 127-150N were supported on an area 42 sq cm, at speeds of 43,000-45,000 rpm and mean clearances of 15-20 microns. Support-worthiness was proved when tested in conjunction with foil journal-bearings and a 19N rotor, excited in a pitching mode by a total unbalance of 43 micron-N.

Licht, L.↗

NASA NTRS1988

An experimental and analytical evaluation of the tapered tension-torsion strap concept

A new free-tip rotor moment controller designed to increase torque output (a restoring moment) was proposed. The controller would be used as a retention device for the freely pitching tip of a helicopter rotor. The new design featured a tapered tension-torsion strap instead of the previously used parellel strap. A tapered strap has a larger separation between the tension wires at the retention end than at the oscillating end; separation is equal at both ends for a parallel strap. A simple dynamic analysis was developed and an experiment performed to evaluate this tapered strap concept. The test results indicated that the torsional spring stiffness of the strap, represented by a torsional pendulum, increased with the amount of taper. The predicted dynamic characteristics of the pendulum also confirmed this observation and correlated reasonably well with the experimental results. It could be concluded from the experimental and analytical results that the tapered strap accomplished increased torque output when compared to the parellel strap.

Louie, Alexander↗

NASA NTRS1997

Measurement Capabilities of Planar Doppler Velocimetry in Large-Scale Wind Tunnels

Over the past few years, Planar Doppler Velocimetry (PDT) has been shown by several laboratories to offer an attractive means for measuring three-dimensional velocity vectors everywhere in a light sheet placed in a flow. Unlike some other optical means of measuring flow velocities, PDT is particularly attractive for use in large wind tunnels where distances to the sample region may be several meters, because it does not require the spatial resolution and tracking of individual scattering particles or the alignment of crossed beams at large distances. To date, demonstrations of PDT (also called Doppler Global Velocimetry by some authors) have been made either in low speed flows without quantitative comparison to other measurements, or in supersonic flows where the Doppler shift is large and its measurement is relatively insensitive to instrumental errors. Moreover, most reported applications have relied on the use of continuous-wave lasers, which limit the measurement to time-averaged velocity fields. This work summarizes the results of two previous studies of PDT in which the use of pulsed lasers to obtain instantaneous velocity vector fields is evaluated. The objective has been to quantitatively define and demonstrate PDT capabilities for applications in large-scale wind tunnels that are intended primarily for the testing of rotorcraft and subsonic aircraft at speeds typically less than 100 m/s. For such applications, the adequate resolution of low-speed flow fields requires accurate measurements of small Doppler shifts that are obtained at distances of several meters from the sample region and with a field of view that is sufficient to encompass the entire region of interest. The use of pulsed lasers provides the unique capability to obtain not only time-averaged fields, but also their statistical fluctuation amplitudes and the spatial excursions of unsteady flow regions such as wakes, separations, and rotor-tip vortices. To accomplish the objectives of these studies, the PDT measurement process was first modeled and its performance evaluated computationally. The noise sources considered included those related to the optical and electronic properties of Charge-Coupled Device (CCD) arrays and to speckle effects associated with the coherent illumination of aerosols from pulsed lasers. The signal noise estimates were incorporated into the PDT signal analysis process and combined with computed scattering signals using a Mae scattering theory for a distributed range of aerosol particle sizes. The results are used to define the necessary instrument configuration, to show that the expected signal levels from a practical PDT system are sufficiently large to allow its useful application in large facilities, and to show that the expected velocity measurement uncertainties are small compared to the mean velocities of interest for most subsonic, large-scale wind tunnel testing, Experimental studies using several bench-top setups are then described that validate the physics of the PDT model and demonstrate the ability to obtain accurate PDT measurements using procedures that are compatible with large-scale wind tunnel operations. The PDT measurement capabilities found in this study lead to the conclusion that PDT offers significant advantages compared to other means of measuring velocity fields in large-scale wind tunnels, including those operating at low speeds.

McKenzie, Robert L.↗

NASA NTRS1974

Computer experiments in preparation of system identification from transient rotor model tests, part 2

System identification methods which can extract model rotor paramenters with reasonable accuracy from noise polluted blade flapping transient measurements were developed. Usually parameter identification requires data on the state variables, that is on deflections and on rate of deflections. The small size of rotor models makes it, however, difficult to measure more than the blade flapping deflections. For the computer experiments it was, therefore, assumed that only noisy deflection measurements are available. Parameter identifications were performed for one and two unknown parameters. Both rotating coordinates and multiblade coordinates were used. It was found that data processing with a digital filter allowed by numerical differentiation a sufficiently accurate determination of the rates of deflection and of the accelerations to obtain reasonable parameter estimates with a simple linear estimator.

Hohenemser, K. H.↗

NASA NTRS1957

Results of turbojet engine operation tests using a 50-50 mixture of JP-4 and tributyl borate as the fuel

An experimental investigation was conducted on a centrifugal-type turbojet engine using a 50-50 mixture of tributyl borate and JP-4 as the fuel to determine the magnitude and the location of the boric oxide deposits in the engine as well as the effect of these deposits on the engine performance. Large deposits of boric acid formed in the combustor walls and on the turbine rotor and stator blades. The deposits had no effect on the engine thrust.

Schafer, Louis J , Jr↗

NASA NTRS1985

Turbine airfoil deposition models and their hot corrosion implications

This research project deals with the prediction of single- and multi-component salt(-solution) deposition, flow and oxide dissolution and their effects on the lifetime of turbine blades. Goals include rationalizing and helping to predict corrosion patterns on operational gas turbine (GT) rotor blades and stator vanes, and ultimately providing some of the tools required to design laboratory simulators and future corrosion resistant high-performance engines. Necessary background developments are reviewed. Results and tentative conclusions for single species (Na sub 2 SO sub 4 (1)) condensation, binary salt-solution (Na sub 2 SO sub 4-K sub 2 SO sub 4) condensation, and burner-rig testing of alloy materials are outlined.

Rosner, D. E.↗

NASA NTRS1990

Three-dimensional viscous rotor flow calculations using a viscous-inviscid interaction approach

A three-dimensional viscous-inviscid interaction analysis was developed to predict the performance of rotors in hover and in forward flight at subsonic and transonic tip speeds. The analysis solves the full-potential and boundary-layer equations by finite-difference numerical procedures. Calculations were made for several different model rotor configurations. The results were compared with predictions from a two-dimensional integral method and with experimental data. The comparisons show good agreement between predictions and test data.

Chen, Ching S.↗

NASA NTRS1990

Three-dimensional viscous rotor flow calculations using a viscous-inviscid interaction approach

Chen, Ching S.↗

NASA NTRS1984

Backup control airstart performance on a digital electronic engine control-equipped F100-engine

The air start capability of a backup control (BUC) was tested for a digital electronic engine control (DEEC) equipped F100 engine, which was installed in an F-15 aircraft. Two air start schedules were tested. Using the group 1 start schedule, based on a 40 sec timer, an air speed of 300 knots was required to ensure successful 40 and 25% BUC mode spooldown airstarts. If core rotor speed (N2) was less than 40% a stall would occur when the start bleed closed, 40 sec after initiation of the air start. All jet fuel starter (JFS) assisted air starts were successful with the group 1 start schedule. For the group 2 schedule, the time between pressurization and start bleed closure ranged between 50 sec and 72 sec. Idle rps was lower than the desired 65% for air starts at higher altitudes and lower air speeds.

Johnson, J. B.↗

NASA NTRS1973

Development of a magnetically suspended momentum wheel

An engineering model of a magnetically suspended momentum wheel was designed, fabricated, and tested under laboratory conditions. The basic unit consisted of two magnet bearings, a sculptured aluminum rotor, brushless dc spin motor, and electronics. The magnet bearings, utilizing rare-earth cobltrat-samarium magnets were active radially and passive axially. The results of the program showed that momentum wheels with magnetic bearings are feasible and operable, and that magnetic bearings of this type are capable of being used for applications where high capacity, high stiffness, and low power consumption are required. The tests performed developed criteria for improved performance for future designs.

Hamilton, S. B.↗

NASA NTRS1977

Lightweight engine containment

Kevlar fabric styles and weaves were studied, as well as methods of application for advanced gas turbine engines. The Kevlar material was subjected to high speed impacts by simple projectiles fired from a rifle, as well as more complex shapes such as fan blades released from gas turbine rotors in a spin pit. Just contained data was developed for a variety of weave and/or application techniques, and a comparative containment weight efficiency was established for Kevlar containment applications. The data generated during these tests is being incorporated into an analytical design system so that blade containment trade-off studies between Kevlar and metal case engine structures can be made. Laboratory tests and engine environment tests were performed to determine the survivability of Kevlar in a gas turbine environment.

Weaver, A. T.↗