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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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At least 919 records · Page 51

Causes of high pressure compressor deterioration in service

The high mechanical reliability and low deterioration rate of the JT9D high-pressure compressor results in long utilization without exceeding engine operational limits. The increasing cost and decreasing supply of fuel have focused attention on the fuel burned implications of such high time use without refurbishment. The paper presents the results of JT9D high pressure compressor studies. The mechanical deterioration of the JT9D high-pressure compressor gaspath parts versus increasing service usage, documented from inspection of service parts, is presented and discussed including changes in airfoil roughness, blade length, airfoil contour and outer air seal trench characteristics. An estimate of the performance loss versus usage is related to each type of damage. The combined estimated high-pressure compressor performance loss for all mechanisms determined from part inspection is compared to historical engine test data to establish the validity of the predicted loss levels. The effect of cold section refurbishment on engine fuel consumption recovery and the results of an optimization study to determine the appropriate interval for high pressure compressor refurbishment are also reported.

Richardson, J. H.↗

Thermal barrier coatings for thermal insulation and corrosion resistance in industrial gas turbine engines

Four thermal barrier coatings were subjected to a 500-hour gas turbine engine test. The coatings were two yttria stabilized zirconias, calcium ortho silicate and calcium meta titanate. The calcium silicate coating exhibited significant spalling. Yttria stabilized zirconia and calcium titanate coatings showed little degradation except in blade leading edge areas. Post-test examination showed variations in the coating due to manual application techniques. Improved process control is required if engineering quality coatings are to be developed. The results indicate that some leading edge loss of the coating can be expected near the tip.

Vogan, J. W.↗

Spark Plug Defects and Tests

The successful operation of the spark plug depends to a large extent on the gas tightness of the plug. Part 1 of this report describes the method used for measuring the gas tightness of aviation spark plugs. Part 2 describes the methods used in testing the electrical conductivity of the insulation material when hot. Part 3 describes the testing of the cold dielectric strength of the insulation material, the resistance to mechanical shock, and the final engine test.

Silsbee, F B↗

Development of a Driver Code for the WICS Project

Wall Interference Correction System (WICS) is a computational technique to evaluate the wind tunnel wall interference corrections for blockage, Mach number, dynamic pressure and angle of attack. The objective is to predict the effects of the bounding walls on wind tunnel measurements [1]. The procedure attempts to compute these corrections in real time so that the test engineer can implement these by adjusting wind tunnel controls for angle of attack and dynamic pressure while the test is in progress in the 12 ft. pressure wind tunnel at the Ames Research Center. The technique utilizes an ideal flow solver PMARC (Panel Method developed at the Ames Research Center) to compute influence coefficients in an internal flow mode by representing a paneled model of the tunnel for fullspan and semispan tests.

Ghosh, Amitabha↗

Support to NASA's Advanced Space Technology Program

During the period of May through September 2000, Lee & Associates, LLC completed the following tasks as specified in the purchase order SOW: Assessment of current processes and structure and recommended improvements; Reviewed and commented on restructure options; Participated in closure of the Fastrac Delta Critical Design Review actions; Participated in the Fastrac Test readiness review (TRR) process for test planned at SSC and Rocketdyne; and Participated in the investigation of any anomalies identified during the Fastrac engine test data reviews.

Goetz, Otto↗

3D Printed Materials Characterization for Rapid Prototyping and Plant Growth

Space Biology experimentation but their effects during plant growth and sanitation have not been documented. With further testing we can determine how certain 3D printed materials affect our plants. The way we tested germination included laying two pieces of germination paper down with the printed petri dish insert of the various material and 14 seeds of Outrageous lettuce to fit in the holes of the insert. We kept an even moisture in all parts by wrapping the petri dishes in two layers of parafilm tape. This project tests over 15 different materials to document performance during plant growth scenarios. This research will not only help space biology but also citizens who use these materials to understand the potential of leaching and ill effects. 3D printing is a recent generally accessed technology with new materials coming out every day. It is important to understand how materials could impact the way the plants grow, and the safety of the food grown. As we continue testing these materials, we will also test engineering properties like tension and elasticity. We have a microbiology team working on this project as well to test biofilm formation. From the germination tests we have completed we have seen little impact on germination rate of these seeds. However, some parts absorb moisture. An ideal material is one that doesn’t leach chemicals or microplastics, can withstand high tension and compression, and doesn’t promote microbial growth. This work is funded by NASA. M. Gandhi was funded by MAIANSE.

Mily Gandhi↗

A Method to Alleviate the Long History Problem Encountered in Monte Carlo Simulations via Weight Window Variance Reduction

When the weight window is implemented in large and complex models, streaming path and deep penetration could lead to a long history problem that takes a disproportionate amount of time for the accomplishment of Monte Carlo simulations and exerts a detrimental effect on the efficiency of parallel computing. An approach set the limitation of weight window splitting was proposed for the alleviation of long history problem. Tests were conducted on a streaming dog-leg geometry model and a 3D model of the Chinese Fusion Engineering Testing Reactor. The results show that a suitable parameter in the alleviation method could optimize both the performance of variance reduction and the efficiency of parallel calculation, which makes long history problem tractable.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Preliminary Results From a Heavily Instrumented Engine Ice Crystal Icing Test in a Ground Based Altitude Test Facility

Preliminary results from the heavily instrumented ALF502R-5 engine test conducted in the NASA Glenn Research Center Propulsion Systems Laboratory are discussed. The effects of ice crystal icing on a full scale engine is examined and documented. This same model engine, serial number LF01, was used during the inaugural icing test in the Propulsion Systems Laboratory facility. The uncommanded reduction of thrust (rollback) events experienced by this engine in flight were simulated in the facility. Limited instrumentation was used to detect icing on the LF01 engine. Metal temperatures on the exit guide vanes and outer shroud and the load measurement were the only indicators of ice formation. The current study features a similar engine, serial number LF11, which is instrumented to characterize the cloud entering the engine, detect/characterize ice accretion, and visualize the ice accretion in the region of interest. Data were acquired at key LF01 test points and additional points that explored: icing threshold regions, low altitude, high altitude, spinner heat effects, and the influence of varying the facility and engine parameters. For each condition of interest, data were obtained from some selected variations of ice particle median volumetric diameter, total water content, fan speed, and ambient temperature. For several cases the NASA in-house engine icing risk assessment code was used to find conditions that would lead to a rollback event. This study further helped NASA develop necessary icing diagnostic instrumentation, expand the capabilities of the Propulsion Systems Laboratory, and generate a dataset that will be used to develop and validate in-house icing prediction and risk mitigation computational tools. The ice accretion on the outer shroud region was acquired by internal video cameras. The heavily instrumented engine showed good repeatability of icing responses when compared to the key LF01 test points and during day-to-day operation. Other noticeable observations are presented.

Enigine Icing↗

Upgrades to Common Data Acquisition System Software Development for NASA's Rocket Propulsion Test Facilities and Software Reuse

Approximately five years ago, the National Aeronautics and Space Administration (NASA) Stennis Space Center (SSC) resumed operation of its large rocket engine test facilities after thirty years of contractor control. During this period, contactors used their own proprietary Data Acquisition System (DAS) to record and process rocket propulsion test data. The transition from a contractor managed facility to a NASA managed facility posed a difficult challenge. In order to support the commercial space launch initiative, SSC needed to develop a software replacement for the contractor proprietary DAS. This replacement software would enable SSC to operate propulsion test facilities more cost effectively and to be more readily able to adapt software for reuse, while at the same time provide internal and external customers with reliable population test data. Therefore, SSC developed in-house, a non-proprietary software suite of applications to replace the previously used proprietary DAS. The requirements for the DAS suite included recording and processing propulsion test data. This capability eliminates the necessity for customers to provide a DAS or rely on a competitor's DAS. An additional benefit of owning the software suite included enabling the ability to add additional features and functionality at a lower cost. The Rocket Propulsion Test (RPT) Program Office reviewed consideration for funding this project with the caveat that development of the software included availability for use with minimal modifications to all SSC test facilities and RPT centers: Marshall Space Flight Center (MSFC), White Sands Test Facility (WSTF), and Glenn Research Center (GRC) Plum Brook Station. Based upon this guideline, SSC created the NASA Data Acquisition System (NDAS) software suite. The ability to use the software at multiple centers, even though each field center uses differing DAS hardware with different capabilities, drove a requirement that the software design be portable with minimal modifications to the software. Then, with software release requirements, evaluations, and approvals completed, the NDAS software suite could also become available to other government agencies, corporations, universities, and the general United States public.

Herbert, Phillip W., Sr.↗

Preliminary Results From a Heavily Instrumented Engine Ice Crystal Icing Test in a Ground Based Altitude Test Facility

Preliminary results from the heavily instrumented ALF502R-5 engine test conducted in the NASA Glenn Research Center Propulsion Systems Laboratory are discussed. The effects of ice crystal icing on a full scale engine is examined and documented. This same model engine, serial number LF01, was used during the inaugural icing test in the Propulsion Systems Laboratory facility. The uncommanded reduction of thrust (rollback) events experienced by this engine in flight were simulated in the facility. Limited instrumentation was used to detect icing on the LF01 engine. Metal temperatures on the exit guide vanes and outer shroud and the load measurement were the only indicators of ice formation. The current study features a similar engine, serial number LF11, which is instrumented to characterize the cloud entering the engine, detect/ characterize ice accretion, and visualize the ice accretion in the region of interest. Data were acquired at key LF01 test points and additional points that explored: icing threshold regions, low altitude, high altitude, spinner heat effects, and the influence of varying the facility and engine parameters. For each condition of interest, data were obtained from some selected variations of ice particle median volumetric diameter, total water content, fan speed, and ambient temperature. For several cases the NASA in-house engine icing risk assessment code was used to find conditions that would lead to a rollback event. This study further helped NASA develop necessary icing diagnostic instrumentation, expand the capabilities of the Propulsion Systems Laboratory, and generate a dataset that will be used to develop and validate in-house icing prediction and risk mitigation computational tools. The ice accretion on the outer shroud region was acquired by internal video cameras. The heavily instrumented engine showed good repeatability of icing responses when compared to the key LF01 test points and during day-to-day operation. Other noticeable observations are presented.

turbomachinery↗

Pulse performance analysis for small hypergolic propellant rocket engines

Small rocket engine tests were conducted for the purpose of obtaining pulse performance data to aid in preliminary design and evaluation of attitude control systems. Both monopropellant and hypergolic bipropellant engines of thrust levels from 5 to 445 N (1 to 100 lb) were tested. The performance data for the hypergolic propellant rockets are compared with theoretical performance calculated from idealized chamber filling and evacuation characteristics. Electromechanical delays in valve response and heat transfer characteristics were found to cause substantial deviation between theoretical performance and test performance. The theoretical analysis is modified to obtain a semiempirical model for hypergolic propellant rockets.

Smith, G. W.↗

Aerosols and Particulates Workshop Sampling Procedures and Venues Working Group Summary

The Sampling Procedures and Venues Workgroup discussed the potential venues available and issues associated with obtaining measurements. Some of the issues included Incoming Air Quality, Sampling Locations, Probes and Sample Systems. The following is a summary of the discussion of the issues and venues. The influence of inlet air to the measurement of exhaust species, especially trace chemical species, must be considered. Analysis procedures for current engine exhaust emissions regulatory measurements require adjustments for air inlet humidity. As a matter of course in scientific investigations, it is recommended that "background" measurements for any species, particulate or chemical, be performed during inlet air flow before initiation of combustion, if possible, and during the engine test period as feasible and practical. For current regulatory measurements, this would be equivalent to setting the "zero" level for conventional gas analyzers. As a minimum, it is recommended that measurements of the humidity and particulates in the incoming air be taken at the start and end of each test run. Additional measurement points taken during the run are desirable if they can be practically obtained. It was felt that the presence of trace gases in the incoming air is not a significant problem. However, investigators should consider the ambient levels and influences of local air pollution for species of interest. Desired measurement locations depend upon the investigation requirements. A complete investigation of phenomenology of particulate formation and growth requires measurements at a number of locations both within the engine and in the exhaust field downstream of the nozzle exit plane. Desirable locations for both extractive and in situ measurements include: (1) Combustion Zone (Multiple axial locations); (2) Combustor Exit (Multiple radial locations for annular combustors); (3) Turbine Stage (Inlet and exit of the stage); (4) Exit Nozzle (Multiple axial locations downstream of the nozzle). Actual locations with potential for extractive or non-intrusive measurements depend upon the test article and test configuration. Committee members expressed the importance of making investigators aware of various ports that could allow access to various stages of the existing engines. Port locations are engine si)ecific and might allow extractive sampling or innovative hybrid optical-probe access. The turbine stage region was one the most desirable locations for obtaining samples and might be accessed through boroscope ports available in some engine designs. Discussions of probes and sampling systems quickly identified issues dependent on particular measurement quantities. With general consensus, the group recommends SAE procedures for measurements and data analyses of currently regulated exhaust species (CO2, CO, THC, NO(x),) using conventional gas sampling techniques. Special procedures following sound scientific practices must be developed as required for species and/or measurement conditions not covered by SAE standards. Several issues arose concerning short lived radicals and highly reactive species. For conventional sampling, there are concerns of perturbing the sample during extraction, line losses, line-wall reactions, and chemical reactions during the sample transport to the analyzers. Sample lines coated with quartz.or other materials should be investigated for minimization of such effects. The group advocates the development of innovative probe techniques and non-intrusive optical techniques for measurement of short lived radicals and highly reactive species that cannot be sampled accurately otherwise. Two innovative probe concepts were discussed. One concept uses specially designed probes to transfer optical beams to and from a region of flow inaccessible by traditional ports or windows. The probe can perturb the flow field but must have a negligible impact on the region to be optically sampled. Such probes are referred to as hybrid probes and are under development at AEDC for measurement in the high pressure, high temperature of a combustor under development for power generation. The other concept consists of coupling an instrument directly to the probe. The probe would isolate a representative sample stream, freeze chemical reactions and direct the sample into the analyzer portion of the probe. Thus, the measurement would be performed in situ without sample line losses due either to reactions or binding at the wall surfaces. This concept was used to develop a fast, in situ, time-of-flight mass spectrometer measurement system for temporal quantification of NO in the IMPULSE facility at AEDC. Additional work is required in this area to determine the best probe and sampling technique for each species measurement requirement identified by the Trace Chemistry Working Group. A partial list of Venues was used as a baseline for discussion. Additional venues were added to the list and the list was broken out into the following categories: (1)Engines (a) Sea Level Test Stands (b) Altitude Chambers; (2) Annular Combustor Test Stands, (3) Sector Flametube Test Stands, (4) Fundamentals Rigs/Experiments.

Pachlhofer, Peter↗

Large scale static tests of a tilt-nacelle V/STOL propulsion/attitude control system

The concept of a combined V/STOL propulsion and aircraft attitude control system was subjected to large scale engine tests. The tilt nacelle/attitude control vane package consisted of the T55 powered Hamilton Standard Q-Fan demonstrator. Vane forces, moments, thermal and acoustic characteristics as well as the effects on propulsion system performance were measured under conditions simulating hover in and out of ground effect.

Source record↗

Full Scale Engine Demonstration of Additively Manufactured High Gamma Prime Turbine Blade

Additive manufacturing (AM), also known as 3D printing, is a rapidly developing technology with tremendous potential in both developmental and production applications. Solar Turbines Incorporated is committed to AM technology development for gas turbine applications. The ability to metal 3D print novel designs of turbine blades capable of actual turbine engine operation would effectively reduce design validation cycle time and allow acquisition of key performance data early in a design campaign. In support of Solar’s advanced manufacturing development and ongoing engine efficiency improvement goals, ORNL and Solar conducted a project to 3D print, machine, inspect, and engine test a full set of Mercury TM 50 stage 2 turbine blades. This full-scale, hot-fired engine demonstration has identified both the capabilities and limitations of the current technologies required to produce turbine hot-section AM components.

36 MATERIALS SCIENCE↗

Fluid infusion system

Performance testing carried out in the development of the prototype zero-g fluid infusion system is described and summarized. Engineering tests were performed in the course of development, both on the original breadboard device and on the prototype system. This testing was aimed at establishing baseline system performance parameters and facilitating improvements. Acceptance testing was then performed on the prototype system to verify functional performance. Acceptance testing included a demonstration of the fluid infusion system on a laboratory animal.

Source record↗

Quiet Clean Short-haul Experimental Engine (QCSEE) Under-The-Wing (UTW) boiler plate nacelle and core exhaust nozzle design report

The mechanical design of the boiler plate nacelle and core exhaust nozzle for the QCSEE under the wing engine is presented. The nacelle, which features interchangeable hard-wall and acoustic panels, is to be utilized in the initial engine testing to establish acoustic requirements for the subsequent composite nacelle as well as in the QCSEE over the wing engine configuration.

Source record↗

Thermal barrier coating life-prediction model development

The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimen procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.

Strangman, T. E.↗

Processes in construction of failure management expert systems from device design information

This paper analyzes the tasks and problem solving methods used by an engineer in constructing a failure management expert system from design information about the device to te diagnosed. An expert test engineer developed a trouble-shooting expert system based on device design information and experience with similar devices, rather than on specific expert knowledge gained from operating the device or troubleshooting its failures. The construction of the expert system was intensively observed and analyzed. This paper characterizes the knowledge, tasks, methods, and design decisions involved in constructing this type of expert system, and makes recommendations concerning tools for aiding and automating construction of such systems.

Malin, Jane T.↗