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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 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

The Development and Use of a Natural Gas / Oxygen Burner Rig for Environmental Barrier Coating and Ceramic Matrix Composite Technology Maturation

This work outlines the development of a new natural gas/oxygen (NG/O2) fueled combustion rig located at the NASA Glenn Research Center for high-temperature environmental durability studies of advanced materials and components at atmospheric pressure. The NG/O2 burner rig can simulate the high-temperature, high-heat flux, and high-velocity thermal environments encountered in gas turbine engines. It also provides the capability to study environmental effects such as water vapor and other foreign contaminants relevant to these applications. The rig is anticipated to bridge the gap between other laboratory methods such as furnaces, jet-fueled burner rigs, high-heat flux lasers, and more expensive engine rig testing. The NG/O2 rig is expected to have maximum sample temperature capabilities over 3,000°F (1,649°C) and result in higher water vapor content compared to our Mach 0.3 to Mach 1.0 jet-A burner rigs which is important for characterizing current and next-generation environmental barrier coatings. This paper will provide an overview of the development of the NG/O2 burner rig, initial characterization, and current research and development efforts on environmental barrier coated ceramic matrix composites.

Burner rig↗
NASA NTRS2000

Novel Vibration Damping of Ceramic Matrix Composite Turbine Blades Developed for RLV Applications

The Reusable Launch Vehicle (RLV) represents the next generation of space transportation for the U.S. space program. The goal for this vehicle is to lower launch costs by an order of magnitude from $10,000/lb to $1,000/lb. Such a large cost reduction will require a highly efficient operation, which naturally will require highly efficient engines. The RS-2200 Linear Aerospike Engine is being considered as the main powerplant for the RLV. Strong, lightweight, temperature-resistant ceramic matrix composite (CMC) materials such as C/SiC are critical to the development of the RS-2200. Preliminary engine designs subject turbopump components to extremely high frequency dynamic excitation, and ceramic matrix composite materials are typically lightly damped, making them vulnerable to high-cycle fatigue. The combination of low damping and high-frequency excitation creates the need for enhanced damping. Thus, the goal of this project has been to develop well-damped C/SiC turbine components for use in the RLV. Foster-Miller and Boeing Rocketdyne have been using an innovative, low-cost process to develop light, strong, highly damped turbopump components for the RS-2200 under NASA s Small Business Innovation Research (SBIR) program. The NASA Glenn Research Center at Lewis Field is managing this work. The process combines three-dimensionally braided fiber reinforcement with a pre-ceramic polymer. The three-dimensional reinforcement significantly improves the structure over conventional two-dimensional laminates, including high through-the-thickness strength and stiffness. Phase I of the project successfully applied the Foster-Miller pre-ceramic polymer infiltration and pyrolysis (PIP) process to the manufacture of dynamic specimens representative of engine components. An important aspect of the program has been the development of the manufacturing process. Results show that the three-dimensionally braided carbon-fiber reinforcement provides good processability and good mechanical stiffness and strength in comparison to materials produced with competing processes as shown in the graphs.

Min, James B.↗
NASA NTRS2013

A Model to Assess the Risk of Ice Accretion Due to Ice Crystal Ingestion in a Turbofan Engine and its Effects on Performance

The occurrence of ice accretion within commercial high bypass aircraft turbine engines has been reported under certain atmospheric conditions. Engine anomalies have taken place at high altitudes that were attributed to ice crystal ingestion, partially melting, and ice accretion on the compression system components. The result was one or more of the following anomalies: degraded engine performance, engine roll back, compressor surge and stall, and flameout of the combustor. The main focus of this research is the development of a computational tool that can estimate whether there is a risk of ice accretion by tracking key parameters through the compression system blade rows at all engine operating points within the flight trajectory. The tool has an engine system thermodynamic cycle code, coupled with a compressor flow analysis code, and an ice particle melt code that has the capability of determining the rate of sublimation, melting, and evaporation through the compressor blade rows. Assumptions are made to predict the complex physics involved in engine icing. Specifically, the code does not directly estimate ice accretion and does not have models for particle breakup or erosion. Two key parameters have been suggested as conditions that must be met at the same location for ice accretion to occur: the local wet-bulb temperature to be near freezing or below and the local melt ratio must be above 10%. These parameters were deduced from analyzing laboratory icing test data and are the criteria used to predict the possibility of ice accretion within an engine including the specific blade row where it could occur. Once the possibility of accretion is determined from these parameters, the degree of blockage due to ice accretion on the local stator vane can be estimated from an empirical model of ice growth rate and time spent at that operating point in the flight trajectory. The computational tool can be used to assess specific turbine engines to their susceptibility to ice accretion in an ice crystal environment.

Jorgenson, Philip C. E.↗
DOE OSTI2017

Additive Manufacturing of Wind Turbine Molds

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

17 WIND ENERGY↗
NASA NTRS1981

An introduction to NASA's turbine engine hot section technology (HOST) project

An overview of research to develop and improve the accuracy of current analysis methods so that increased durability can be designed into future engines is presented. Emphasis is placed on improved accuracy in life prediction. Component design, including description of the thermal and aerodynamic environments, the material's mechanical response, the interactions between environmental and structural response, and high temperature instrumentation capable of measuring near-engine environment effects are addressed. Component tests, improved modeling of the physical phenomena, and tests to verify the proved models are also discussed.

Gauntner, D. J.↗
NASA NTRS1984

High temperature static strain gage program

Development of electrical resistance strain gages for static strain measurements of nickel or cobalt superalloy parts inside a gas turbine engine on a test stand was inititated. Measurements of this type are of great importance because without reliable knowledge of the stresses and strains which exist in specific components, it will be difficult to fully appreciate where improvements in design and materials can be implemented. The first part of this effort consists of a strain gage alloy development program which will be followed by an investigation of complete strain gage systems. Efforts to date are summarized.

Hulse, C.↗
NASA NTRS2004

Fault Tolerant Magnetic Bearing Testing and Conical Magnetic Bearing Development for Extreme Temperature Environments

During the six month tenure of the grant, activities included continued research of hydrostatic bearings as a viable backup-bearing solution for a magnetically levitated shaft system in extreme temperature environments (1000 F), developmental upgrades of the fault-tolerant magnetic bearing rig at the NASA Glenn Research Center, and assisting in the development of a conical magnetic bearing for extreme temperature environments, particularly turbomachinery. It leveraged work from the ongoing Smart Efficient Components (SEC) and the Turbine-Based Combined Cycle (TBCC) program at NASA Glenn Research Center. The effort was useful in providing technology for more efficient and powerful gas turbine engines.

Keith, Theo G., Jr.↗
NASA NTRS2016

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.

O'Neal, Derek↗
NASA NTRS2016

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. This paper discusses the impacts of the DMLS fabrication technique on the design of the turbopump and lessons learned during DMLS hardware fabrication and material testing.

O’Neal, T. Derek↗
NASA NTRS2023

The Development and Use of a Natural Gas / Oxygen Burner Rig for Environmental Barrier Coating and Ceramic Matrix Composite Technology Maturation

This work outlines the development of a new natural gas/oxygen (NG/O 2 ) fueled combustion rig located at the NASA Glenn Research Center for high-temperature environmental durability studies of advanced materials and components at atmospheric pressure. The NG/O 2 burner rig can simulate the high-temperature, high-heat flux, and high-velocity thermal environments encountered in gas turbine engines. It also provides the capability to study environmental effects such as water vapor and other foreign contaminants relevant to these applications. The rig is anticipated to bridge the gap between other laboratory methods such as furnaces, jet-fueled burner rigs, high-heat flux lasers, and more expensive engine rig testing. The NG/O 2 rig is expected to have maximum sample temperature capabilities over 3,000°F (1,649°C) and result in higher water vapor content compared to our Mach 0.3 to Mach 1.0 jet-A burner rigs which is important for characterizing current and next-generation environmental barrier coatings. This paper will provide an overview of the development of the NG/O 2 burner rig, initial characterization, and current research and development efforts on environmental barrier coated ceramic matrix composites.

Burner rig↗
NASA NTRS1982

Development of high strength, high temperature ceramics

Improvement in the high-pressure turbopumps, both fuel and oxidizer, in the Space Shuttle main engine were considered. The operation of these pumps is limited by temperature restrictions of the metallic components used in these pumps. Ceramic materials that retain strength at high temperatures and appear to be promising candidates for use as turbine blades and impellers are discussed. These high strength materials are sensitive to many related processing parameters such as impurities, sintering aids, reaction aids, particle size, processing temperature, and post thermal treatment. The specific objectives of the study were to: (1) identify and define the processing parameters that affect the properties of Si3N4 ceramic materials, (2) design and assembly equipment required for processing high strength ceramics, (3) design and assemble test apparatus for evaluating the high temperature properties of Si3N4, and (4) conduct a research program of manufacturing and evaluating Si3N4 materials as applicable to rocket engine applications.

Hall, W. B.↗
DOE OSTI2020

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps

As wind turbine blades continue to scale in length and total mass, the acceptability of traditional approaches for the engineering of processes to build these products has reached a limit. The continued need to reduce the levelized cost of energy (LCOE) drives manufacturing cycle times lower and the net mass of critical components challenges even the most experienced fabricators to meet the quality requirements for safe operating performance over the 25-year design life of the blade. In trying to reduce cycle time for key components of wind turbines, manufacturers discovered occasional buckling of fibers in wind turbine blade spar caps. The cause of the buckling was unknown. The goal of this project was to show that a comprehensive simulation, which considered all of the physics of the VARTM process, could identify the cause of the fiber buckling in spar caps that has been observed during the manufacturing process. Ultimately, the simulation determined the manufacturing process and parameters could lead to significant compressive stresses in the fibers eventually causing buckling. Simulation results suggest that the stress introduced from friction is the largest source of compressive stress in the fibers, the stress from the weight of gravity is significant but secondary, and the compressive stress from cure shrinkage does not play a significant role in the buckling of fibers. This report provides details of the testing and simulation methodology used to identify the cause of the fiber buckling.

17 WIND ENERGY↗
NASA NTRS1957

Component Performance Investigation of J71 Experimental Turbine VII: Effect of First-stator Adjustment; Over-all Performance of J71-97 Turbine with 87-percent-design Stator Area

The performance results, as well as a compressor-turbine match point study based on a particular mode of engine operation, are compared with those previously obtained with the same turbine having first-stator areas 70, 95.6, and 132 percent of design. Maximum efficiencies for all turbine configurations were high, on the order of 87 to 89 percent. The efficiencies obtained at the match points for the 87-, 95.6-, and 132-percent turbines were slightly lower. No match point for the 70-percent turbine was obtained because, with first-stator areas less than 75.5 percent of design, the turbine would develop insufficient work to drive the compressor at the match point.

Schum, Harold J↗
NASA NTRS1982

Energy efficient engine. Low pressure turbine test hardware detailed design report

The low pressure turbine for the energy efficient engine is a five-stage configuration with moderate aerodynamic loading incorporating advanced features of decambered airfoils and extended blade overlaps at platforms and shrouds. Mechanical integrity of 18,000 hours on flowpath components and 36,000 hours on all other components is achieved along with no aeromechanical instabilities within the steady-state operating range. Selection of a large number (156) of stage 4 blades, together with an increased stage 4 vane-to-blade gap, assists in achieving FAR 36 acoustic goals. Active clearance control (ACC) of gaps at blade tips and interstage seals is achieved by fan air cooling judiciously applied at responsive locations on the casing. This ACC system is a major improvement in preventing deterioration of the 0.0381 cm (0.015 in.) clearances required to meet the integrated-core/low-spool turbine efficiency goal of 91.1% and the light propulsion system efficiency goal of 91.7%.

Cherry, D. G.↗
NASA NTRS1984

Coating Life Prediction

Hot-section gas-turbine components typically require some form of coating for oxidation and corrosion protection. Efficient use of coatings requires reliable and accurate predictions of the protective life of the coating. Currently engine inspections and component replacements are often made on a conservative basis. As a result, there is a constant need to improve and develop the life-prediction capability of metallic coatings for use in various service environments. The purpose of this present work is aimed at developing of an improved methodology for predicting metallic coating lives in an oxidizing environment and in a corrosive environment.

Nesbitt, J. A.↗
NASA NTRS1992

Time-averaged heat transfer and pressure measurements and comparison with prediction for a two-stage turbine

Time-averaged Stanton number and surface-pressure distributions are reported for the first-stage vane row and the first-stage blade row of the Rocketdyne Space Shuttle Main Engine two-stage fuel-side turbine. These measurements were made at 10 percent, 50 percent, and 90 percent span on both the pressure and suction surfaces of the component. Stanton-number distributions are also reported for the second-stage vane at 50 percent span. A shock tube is used as a short-duration source of heated and pressurized air to which the turbine is subjected. Platinum thin-film gages are used to obtain the heat-flux measurements and miniature silicone-diaphragm pressure transducers are used to obtain the surface pressure measurements. The first-stage vane Stanton number distributions are compared with predictions obtained using a quasi-3D Navier-Stokes solution and a version of STAN5. This same N-S technique was also used to obtain predictions for the first blade and the second vane.

Dunn, M. G.↗
NASA NTRS1995

Performance seeking control (PSC) for the F-15 highly integrated digital electronic control (HIDEC) aircraft

The performance seeking control algorithm optimizes total propulsion system performance. This adaptive, model-based optimization algorithm has been successfully flight demonstrated on two engines with differing levels of degradation. Models of the engine, nozzle, and inlet produce reliable, accurate estimates of engine performance. But, because of an observability problem, component levels of degradation cannot be accurately determined. Depending on engine-specific operating characteristics PSC achieves various levels performance improvement. For example, engines with more deterioration typically operate at higher turbine temperatures than less deteriorated engines. Thus when the PSC maximum thrust mode is applied, for example, there will be less temperature margin available to be traded for increasing thrust.

Orme, John S.↗
NASA NTRS1996

Nuclear Magnetic Resonance Used to Quantify the Effect of Pyrolysis Conditions on the Oxidative Stability of Silicon Oxycarbide Ceramics

This work was undertaken in support of the Low Cost Ceramic Composite Virtual Company, (LC^3), whose members include Northrop Grumman Corporation, AlliedSignal Inc., and Allison Advanced Development Company. LC^3 is a cost-shared effort funded by the Advanced Research Projects Agency (ARPA) and the LC^3 participants to develop a low-cost fabrication methodology for manufacturing ceramic matrix composite structural components. The program, which is being administered by the U.S. Air Force Wright Laboratory Materials Directorate, is focused on demonstrating a ceramic matrix composite turbine seal for a regional aircraft engine. This part is to be fabricated by resin transfer molding of a siloxane polymer into a fiber preform that will be transformed into a ceramic by pyrolytic conversion.

Source record↗