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At least 955 records · Page 53

Thick thermal barrier coatings for diesel engines

Caterpillar's approach to applying thick thermal barrier coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective Caterpillar's program to date has been to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impeded the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Beardsley, M. Brad↗

A Pre-Mixed Shock-Induced-Combustion Approach to Inlet and Combustor Design for Hypersonic Applications

The need for efficient access to space has created interest in airbreathing propulsion as a means of achieving that goal. The NASP program explored a single-stage-to-orbit approach which could require scramjet airbreathing propulsion out to Mach 16 to 20. Recent interest in global access could require hypersonic cruise engines operating efficiently in the Mach 10 to 12 speed range. A common requirement of both these types of propulsion systems is that they would have to be fully integrated with the aero configuration so that the forebody becomes a part of the external compression inlet and the nozzle expansion is completed on the vehicle aftbody.

Weidner, John P.↗

Designing for Maintainability and System Availability

The final goal for a delivered system (whether a car, aircraft, avionics box or computer) should be its availability to operate and perform its intended function over its expected design life. Hence, in designing a system, we cannot think in terms of delivering the system and just walking away. The system supplier needs to provide support throughout the operating life of the product. Here, supportability requires an effective combination of reliability, maintainability, logistics and operations engineering (as well as safety engineering) to have a system that is available for its intended use throughout its designated mission lifetime. Maintainability is a key driving element in the effective support and upkeep of the system as well as providing the ability to modify and upgrade the system throughout its lifetime. This paper then, will concentrate on maintainability and its integration into the system engineering and design process. The topics to be covered include elements of maintainability, the total cost of ownership, how system availability, maintenance and logistics costs and spare parts cost effect the overall program costs. System analysis and maintainability will show how maintainability fits into the overall systems approach to project development. Maintainability processes and documents will focus on how maintainability is to be performed and what documents are typically generated for a large scale program. Maintainability analysis shows how trade-offs can be performed for various alternative components. The conclusions summarize the paper and are followed by specific problems for hands-on training.

Lalli, Vincent R.↗

Turbulence Studies of a Rectangular Slotted Noise-Suppressor Nozzle

The problem of noise suppression of turbojet engines has shown a need for turbulence data within the flow field of various types of nozzles used in ad hoc investigations of the sound power. The result of turbulence studies in a nozzle configuration of four parallel rectangular slots is presented in this report with special attention to the effect of the spacing of the nozzles on the intensity of turbulence, scale of turbulence, spectrum of turbulence, and the mean stream velocity. Taylor's hypothesis, which describes the convection of the turbulence eddies, was tested and found correct within experimental error and certain experimental and theoretical limitations. The convection of the pressure patterns was also investigated, and the value of the convection velocity was found to be about 0.43 times the central core velocity of the jets. The effect of the spacing-to-width ratio of the nozzles upon the turbulence intensity, the scale of turbulence, and the spectral distribution of the noise was found in general to produce a maximum change for spacing-to-width ratios of 1.5 to 2.0. These changes may be the cause of the reduction in sound power reported for similar full-scale nozzles and test conditions under actual (static) engine operation. A noise reduction parameter is defined from Lighthill's theory which gives qualitative agreement with experiments which show the noise reduction is greatest for spacing-to-width ratios of 1.5 to 2.0.

Laurence, James C.↗

STOL Characteristics of a Propeller-Driven, Aspect-Ratio-10, Straight-Wing Airplane with Boundary-Layer Control Flaps, as Estimated from Large-Scale Wind-Tunnel Tests

A study is presented of the improvements in take-off and landing distances possible with a conventional propeller-driven transport-type airplane when the available lift is increased by propeller slipstream effects and by very effective trailing-edge flaps and ailerons. This study is based on wind-tunnel tests of a 45-foot span, powered model, with BLC on the trailing-edge flaps and controls. The data were applied to an assumed airplane with four propellers and a wing loading of 50 pounds per square foot. Also included is an examination of the stability and control problems that may result in the landing and take-off speed range of such a vehicle. The results indicated that the landing and take-off distances could be more than halved by the use of highly effective flaps in combination with large amounts of engine power to augment lift (STOL). At the lowest speeds considered (about 50 knots), adequate longitudinal stability was obtained but the lateral and directional stability were unsatisfactory. At these low speeds, the conventional aerodynamic control surfaces may not be able to cope with the forces and moments produced by symmetric, as well as asymmetric, engine operation. This problem was alleviated by BLC applied to the control surfaces.

Weiberg, James A↗

Internal-Performance Evaluation of Two Fixed-Divergent-Shroud Ejectors

Ejectors designed for use in a Mach 2.2 aircraft were evaluated over a range of representative primary pressure ratios and ejector corrected weight-flow ratios. Basic thrust and pumping characteristics are discussed in terms of an assumed engine operating schedule to illustrate the variation of performance with Mach number. The two designs differed about 16 percent in the shroud longitudinal spacing ratio. For corrected ejector weight-flow ratios up to 0.10, the performance of the fixed-shroud ejector designs is comparable with that of a similar continuously variable ejector except at conditions corresponding to acceleration with afterburning from Mach 0.4 to 1.2. In this region, the ejector thrust ratio decreased to a minimum of 0.96.

Mihaloew, James R.↗

Summary of Rocketdyne Engine A5 Rocket Based Combined Cycle Testing

Rocketdyne Propulsion and Power (RPP) has completed a highly successful experimental test program of an advanced rocket based combined cycle (RBCC) propulsion system. The test program was conducted as part of the Advanced Reusable Technology program directed by NASA-MSFC to demonstrate technologies for low-cost access to space. Testing was conducted in the new GASL Flight Acceleration Simulation Test (FAST) facility at sea level (Mach 0), Mach 3.0 - 4.0, and vacuum flight conditions. Significant achievements obtained during the test program include 1) demonstration of engine operation in air-augmented rocket mode (AAR), ramjet mode and rocket mode and 2) smooth transition from AAR to ramjet mode operation. Testing in the fourth mode (scramjet) is scheduled for November 1998.

Ketchum. A.↗

Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved, lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbocharging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗

Process for Making Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved. lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbo-charging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗

Probabilistic Analysis of Aircraft Gas Turbine Disk Life and Reliability

Two series of low cycle fatigue (LCF) test data for two groups of different aircraft gas turbine engine compressor disk geometries were reanalyzed and compared using Weibull statistics. Both groups of disks were manufactured from titanium (Ti-6Al-4V) alloy. A NASA Glenn Research Center developed probabilistic computer code Probable Cause was used to predict disk life and reliability. A material-life factor A was determined for titanium (Ti-6Al-4V) alloy based upon fatigue disk data and successfully applied to predict the life of the disks as a function of speed. A comparison was made with the currently used life prediction method based upon crack growth rate. Applying an endurance limit to the computer code did not significantly affect the predicted lives under engine operating conditions. Failure location prediction correlates with those experimentally observed in the LCF tests. A reasonable correlation was obtained between the predicted disk lives using the Probable Cause code and a modified crack growth method for life prediction. Both methods slightly overpredict life for one disk group and significantly under predict it for the other.

Melis, Matthew E.↗

A Comparative Study of High and Low Fidelity Fan Models for Turbofan Engine System Simulation

In this paper, a heterogeneous propulsion system simulation method is presented. The method is based on the formulation of a cycle model of a gas turbine engine. The model includes the nonlinear characteristics of the engine components via use of empirical data. The potential to simulate the entire engine operation on a computer without the aid of data is demonstrated by numerically generating "performance maps" for a fan component using two flow models of varying fidelity. The suitability of the fan models were evaluated by comparing the computed performance with experimental data. A discussion of the potential benefits and/or difficulties in connecting simulations solutions of differing fidelity is given.

Reed, John A.↗

Liquid Methane/Liquid Oxygen Injectors for Potential Future Mars Ascent Engines

Preliminary mission studies for human exploration of Mars have been performed at Marshall Space Flight Center (MSFC). These studies indicate that for chemical rockets only a cryogenic propulsion system would provide high enough performance to be considered for a Mars ascent vehicle. Although the mission is possible with Earth-supplied propellants for this vehicle, utilization of in-situ propellants is highly attractive. This option would significantly reduce the overall mass of launch vehicles. Consequently, the cost of the mission would be greatly reduced because the number and size of the Earth launch vehicle(s) needed for the mission would decrease. NASA/Johnson Space Center has initiated several concept studies of in-situ propellant production plants. Liquid oxygen (LOX) is the primary candidate for an in-situ oxidizer. In-situ fuel candidates include methane (CH4), ethylene (C2H4), and methanol (CH3OH). MSFC initiated a technology development program for a cryogenic propulsion system for the Mars human exploration mission in 1998. One part of this technology program is the effort described here: an evaluation of propellant injection concepts for a LOX/liquid methane Mars Ascent Engine (MAE) with an emphasis on light-weight, high efficiency, reliability, and thermal compatibility. In addition to the main objective, hot-fire tests of the subject injectors will be used to test other key technologies including light-weight combustion chamber materials and advanced ignition concepts. This paper will address the results of the liquid methane/LOX injector study conducted at MSFC. A total of four impinging injector configurations were tested under combustion conditions in a modular combustor test article (MCTA), equipped with optically accessible windows. A series of forty hot-fire tests, which covered a wide range of engine operating conditions with the chamber pressure varied from 320 to 510 and the mixture ratio from 1.5 to 3.5, were performed. The test matrix also included a variation in the combustion chamber length for the purpose of investigating its effects on the combustion performance and stability.

Trinh, Huu Phuoc↗

Reuse fo a Cold War Surveillance Drone to Flight Test a NASA Rocket Based Combined Cycle Engine

Plans for and early feasibility investigations into the modification of a Lockheed D21B drone to flight test the DRACO Rocket Based Combined Cycle (RBCC) engine are discussed. Modifications include the addition of oxidizer tanks, modern avionics systems, actuators, and a vehicle recovery system. Current study results indicate that the D21B is a suitable candidate for this application and will allow demonstrations of all DRACO engine operating modes at Mach numbers between 0.8 and 4.0. Higher Mach numbers may be achieved with more extensive modification. Possible project risks include low speed stability and control, and recovery techniques.

Brown, T. M.↗

Liquid Methane/Oxygen Injector Study for Mars Ascent Engines

As a part of the advancing technology of the cryogenic propulsion system for the Mars exploration mission, this effort aims at evaluating propellant injection concepts for liquid methane/liquid oxygen (LOX) rocket engines. Split-triplet and unlike impinging injectors were selected for this study. A total of four injector configurations were tested under combustion conditions in a modular combustor test article (MCTA), equipped with optically accessible windows, at MSFC. A series of forty hot-fire tests, which covered a wide range of engine operating conditions with the chamber pressure ranging from 320 to 510 and the mixture ratio from 1.5 to 3.5, were conducted. The test matrix also included a variation in the combustion chamber length for the purpose of investigating its effects on the combustion performance and stability. Initial assessments of the test results showed that the injectors provided stable combustion and there were no injector face overheating problems under all operating conditions. The Raman scattering signal measurement method was successfully demonstrated for the hydrocarbon/oxygen reactive flow field. The near-injector face flow field was visually observed through the use of an infrared camera. Chamber wall temperature, high frequency chamber pressure, and average throat section heat flux were also recorded throughout the test series. Assessments of the injector performance are underway.

Trinh, Huu Phuoc↗

Preliminary Design of Low-Thrust Interplanetary Missions

For interplanetary missions, highly efficient electric propulsion systems can be used to increase the mass delivered to the destination and/or reduce the trip time over typical chemical propulsion systems. This technology is being demonstrated on the Deep Space 1 mission - part of NASA's New Millennium Program validating technologies which can lower the cost and risk and enhance the performance of future missions. With the successful demonstration on Deep Space 1, future missions can consider electric propulsion as a viable propulsion option. Electric propulsion systems, while highly efficient, produce only a small amount of thrust. As a result, the engines operate during a significant fraction of the trajectory. This characteristic makes it much more difficult to find optimal trajectories. The methods for optimizing low-thrust trajectories are typically categorized as either indirect, or direct. Indirect methods are based on calculus of variations, resulting in a two-point boundary value problem that is solved by satisfying terminal constraints and targeting conditions. These methods are subject to extreme sensitivity to the initial guess of the variables - some of which are not physically intuitive. Adding a gravity assist to the trajectory compounds the sensitivity. Direct methods parameterize the problem and use nonlinear programming techniques to optimize an objective function by adjusting a set of variables. A variety of methods of this type have been examined with varying results. These methods are subject to the limitations of the nonlinear programming techniques. In this paper we present a direct method intended to be used primarily for preliminary design of low-thrust interplanetary trajectories, including those with multiple gravity assists. Preliminary design implies a willingness to accept limited accuracy to achieve an efficient algorithm that executes quickly.

Sims, Jon A.↗

Data Oscillation Resolution of Propellant Flowmeter Used in FASTRAC Engine Testing

The Stennis Space Centers' horizontal test facility, Marshall Space Flight Centers' propulsion test article and the X-34 flight vehicle are designed with V-cone flowmeters for measurement of both RP-1 and LOX flow-rates for Fastrac engine testing. Delta pressure transducer data from these flowmeters are used to calibrate the RP-1 and LOX mixture ratio in the Fastrac engine. Data from the V-Cone flowmeter delta pressure transducers have excessive oscillation. The delta pressure oscillations have caused flowrate data fluctuations that interfered with making the accurate readings necessary to calibrate the RP-1 and LOX mixture ratio required for Fastrac engine operation. The objective of this report is to document the flowmeter data oscillation problem and the method used to obtain more reliable flowmeter data.

Heflin, J.↗

The Effect of Boron on the Low Cycle Fatigue Behavior of Disk Alloy KM4

The durability of powder metallurgy nickel base superalloys employed as compressor and turbine disks is often limited by low cycle fatigue (LCF) crack initiation and crack growth from highly stressed surface locations (corners, holes, etc.). Crack growth induced by dwells at high stresses during aerospace engine operation can be particularly severe. Supersolvus solution heat treatments can be used to produce coarse grain sizes approaching ASTM 6 for improved resistance to dwell fatigue crack growth. However, the coarse grain sizes reduce yield strength, which can lower LCF initiation life. These high temperature heat treatments also can encourage pores to form. In the advanced General Electric disk superalloy KM4, such pores can initiate fatigue cracks that limit LCF initiation life. Hot isostatic pressing (HIP) during the supersolvus solution heat treatment has been shown to improve LCF initiation life in KM4, as the HIP pressure minimizes formation of the pores. Reduction of boron levels in KM4 has also been shown to increase LCF initiation life after a conventional supersolvus heat treatment, again possibly due to effects on the formation tendencies of these pores. However, the effects of reduced boron levels on microstructure, pore characteristics, and LCF failure modes in KM4 still need to be fully quantified. The objective of this study was to determine the effect of boron level on the microstructure, porosity, LCF behavior, and failure modes of supersolvus heat treated KM4.

Gabb, Timothy↗

STS-104 Countdown Status Briefing

George Diller, NASA Public Affairs, introduces Jeff Spaulding, NASA Test Director, Louie Garcia, STS-104 Operations Engineer, and Ed Priselac, Shuttle Weather Officer, in this launch minus one day press conference. An overview is given of the launch vehicle status, countdown procedures, payload status, and weather forecast. The men then answer questions from the press.

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