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NASA NTRS1992

Site partitioning for distributed redundant disk arrays

Distributed redundant disk arrays can be used in a distributed computing system or database system to provide recovery in the presence of temporary and permanent failures of single sites. In this paper, we look at the problem of partitioning the sites into redundant arrays in such way that the communication costs for maintaining the parity information are minimized. We show that the partitioning problem is NP-complete and we propose two heuristic algorithms for finding approximate solutions.

Mourad, Antoine N.↗

NASA NTRS1994

Forced response of mistuned bladed disks

Small mistuning can cause large, catastrophic changes in blade vibrational response whereby the amplitudes of vibration of some blades may increase by several hundred percent. This can produce 'rogue' blades and HCF failure. The free and forced responses may be highly sensitive to mistuning, and the tuned system predictions may be qualitatively in error and grossly underestimate blade forced response and overestimate fatigue life. Manufacturing tolerances, material non-uniformities, nonidentical root fixtures, and in-service degradation result in blade-to-blade differences that destroy cyclic symmetry in bladed discs. Therefore, a credible forced response prediction system for turbomachinery vibration must take mistuning into account. This report addresses these problems, states several objectives, and introduces NASA research program thrusts concerning this problem. This report was given during the NASA LeRC Workshop on Forced Response in Turbomachinery in August of 1993.

Pierre, Christophe↗

NASA NTRS2001

Deformation and Life Analysis of Composite Flywheel Disk and Multi-disk Systems

In this study an attempt is made to put into perspective the problem of a rotating disk, be it a single disk or a number of concentric disks forming a unit. An analytical model capable of performing an elastic stress analysis for single/multiple, annular/solid, anisotropic/isotropic disk systems, subjected to both pressure surface tractions, body forces (in the form of temperature-changes and rotation fields) and interfacial misfits is derived and discussed. Results of an extensive parametric study are presented to clearly define the key design variables and their associated influence. In general the important parameters were identified as misfit, mean radius, thickness, material property and/or load gradation, and speed; all of which must be simultaneously optimized to achieve the "best" and most reliable design. Also, the important issue of defining proper performance/merit indices (based on the specific stored energy), in the presence of multiaxiality and material anisotropy is addressed. These merit indices are then utilized to discuss the difference between flywheels made from PMC and TMC materials with either an annular or solid geometry. Finally two major aspects of failure analysis, that is the static and cyclic limit (burst) speeds are addressed. In the case of static limit loads, upper, lower, and out-of-plane bounds for disks with constant thickness are presented for both the case of internal pressure loading (as one would see in a hydroburst test) and pure rotation (as in the case of a free spinning disk). The results (interaction diagrams) are displayed graphically in designer friendly format. For the case of fatigue, a representative fatigue/life master curve is illustrated in which the normalized limit speed versus number of applied cycles is given for a cladded TMC disk application.

Arnold, S. M.↗

NASA NTRS1960

A Solid Film Lubricant Composition for Use at High Sliding Velocities in Liquid Nitrogen

Solid-lubricant-containing compositions can be of value as films and solid bodies for bearing and seal surfaces in low-temperature liquefied gases. An experimental composition including polytetrafluoroethylene (PTFE), an epoxy resin, and lithium-alumina-silicate was studied in friction, wear, and endurance experiments in liquid nitrogen (−320 F). This composition was formulated to approximate the thermal expansion of metals used in cryogenic systems. Hemisphere (3/6-in. radius) rider specimens were used and in most experiments the load was 1000 g. Films (0.005-in. thick) on disk specimens gave good endurance life, low rider wear, and desirable friction (f = 0.02 to 0.07). They functioned at a higher sliding velocity (no failure at 16, 000 ft/min) with copper rider specimens than with stainless steel riders (failure at 9000 ft/min). Solid rider material of the experimental composition had good friction and wear properties at sliding velocities above 4000 ft/min. It is important to use the experimental composition with mating materials having good thermal conductivity.

Wisander, D. W.↗

NASA NTRS1997

Nonlinear Dynamic Analysis of Disordered Bladed-Disk Assemblies

In a effort to address current needs for efficient, air propulsion systems, we have developed some new analytical predictive tools for understanding and alleviating aircraft engine instabilities which have led to accelerated high cycle fatigue and catastrophic failures of these machines during flight. A frequent cause of failure in Jets engines is excessive resonant vibrations and stall flutter instabilities. The likelihood of these phenomena is reduced when designers employ the analytical models we have developed. These prediction models will ultimately increase the nation's competitiveness in producing high performance Jets engines with enhanced operability, energy economy, and safety. The objectives of our current threads of research in the final year are directed along two lines. First, we want to improve the current state of blade stress and aeromechanical reduced-ordered modeling of high bypass engine fans, Specifically, a new reduced-order iterative redesign tool for passively controlling the mechanical authority of shroudless, wide chord, laminated composite transonic bypass engine fans has been developed. Second, we aim to advance current understanding of aeromechanical feedback control of dynamic flow instabilities in axial flow compressors. A systematic theoretical evaluation of several approaches to aeromechanical feedback control of rotating stall in axial compressors has been conducted. Attached are abstracts of two .papers under preparation for the 1998 ASME Turbo Expo in Stockholm, Sweden sponsored under Grant No. NAG3-1571. Our goals during the final year under Grant No. NAG3-1571 is to enhance NASA's capabilities of forced response of turbomachines (such as NASA FREPS). We with continue our development of the reduced-ordered, three-dimensional component synthesis models for aeromechanical evaluation of integrated bladeddisk assemblies (i.e., the disk, non-identical bladeing etc.). We will complete our development of component systems design optimization strategies for specified vibratory stresses and increased fatigue life prediction of assembly components, and for specified frequency margins on the Campbell diagrams of turbomachines. Finally, we will integrate the developed codes with NASA's turbomachinery aeromechanics prediction capability (such as NASA FREPS).

McGee, Oliver G., III↗

NASA NTRS1984

Helium hammer in superfluid transfer

Large transient pressure pulses, referred to as a helium hammer, which occurred in the transfer line of the main cryogenic tank during the development tests of the Infrared Astronomical Satellite, launched on January 25, 1983, are analyzed, and the measures taken to prevent a failure described. The modifications include an installation of a 2.3-liter surge tank upstream, and a back-up relief valve downstream, of a burst disk. The surge tank is designed to attenuate a 0.33-MPa pressure pulse at the inlet down to 0.092 MPa at the outlet. A mechanism of the pulse generation is suggested, which involves flashing and rapid recondensation of the small amount of liquid entering the warm section of a transition to room temperature.

Tward, E.↗

NASA NTRS2000

Dynamic Stall Characteristics of Drooped Leading Edge Airfoils

Helicopters in high-speed forward flight usually experience large regions of dynamic stall over the retreating side of the rotor disk. The rapid variations in the lift and pitching moments associated with the stall process can result in vibratory loads, and can cause fatigue and failure of pitch links. In some instances, the large time lag between the aerodynamic forces and the blade motion can trigger stall flutter. A number of techniques for the alleviation of dynamic stall have been proposed and studied by researchers. Passive and active control techniques have both been explored. Passive techniques include the use of high solidity rotors that reduce the lift coefficients of individual blades, leading edge slots and leading edge slats. Active control techniques include steady and unsteady blowing, and dynamically deformable leading edge (DDLE) airfoils. Considerable amount of experimental and numerical data has been collected on the effectiveness of these concepts. One concept that has not received as much attention is the drooped-leading edge airfoil idea. It has been observed in wind tunnel studies and flight tests that drooped leading edge airfoils can have a milder dynamic stall, with a significantly milder load hysteresis. Drooped leading edge airfoils may not, however, be suitable at other conditions, e.g. in hover, or in transonic flow. Work needs to be done on the analysis and design of drooped leading edge airfoils for efficient operation in a variety of flight regimes (hover, dynamic stall, and transonic flow). One concept that is worthy of investigation is the dynamically drooping airfoil, where the leading edge shape is changed roughly once-per-rev to mitigate the dynamic stall.

Sankar, Lakshmi N.↗

NASA NTRS2003

Mechanical Behavior of Advanced Materials for Aerospace Applications

The purpose of this study was to determine whether High Cycle Fatigue (HCF) loading has any deleterious synergistic effect on life when combined with the typical Low Cycle Fatigue (LCF) loading present in engine disks. This interaction is particularly important in the rim region of blisk applications, where fatigue initiations from vibratory stresses (HCF) may be propagated to the disk by LCF. The primary effort in this study was focused on determining and documenting initiation sites and damage mechanisms. Under LCF loading conditions the failures were predominantly surface initiated, while HCF loading favored internal initiations. Deleterious HCF/LCF interactions would always result in a transition from internal to surface initiations. The results indicated that under the relative stress conditions evaluated there was no interaction between HCF and LCF. In FY99 this effort was extended to investigate several other loading conditions (R-ratio effects) as well as interactions between LCF and two-hour tensile dwells. The results will be published as a NASA Technical Memorandum.

Telesman, Ignancy↗

NASA NTRS1979

Mechanisms of graphite fluoride /CFx/n lubrication

Friction, wear and wear life results were compared with optical microscope observations as a function of sliding distance for graphite fluoride rubbed films applied to three surface finishes - polished, sanded and sandblasted. The lubricating process consisted of the plastic flow of thin films of graphite fluoride between flat areas on the rider and on the metallic substrate. If the substrate was rough, flat areas were created during run-in, and the graphite fluoride (CFx)n flowed across them. Wear life was enhanced by restricting radial (or transverse) flow of the graphite fluoride from the contact region by increasing surface roughness. Valleys in the roughened substrate surface served as a reservoir for graphite fluoride and as a deposit site for wear debris. Failure resulted from the gradual depletion of graphite fluoride from the contact region with the subsequent formation of powdery metallic debris that covered both rider and disk surfaces

Fusaro, R. L.↗

NASA NTRS1983

Evaluation of feasibility of measuring EHD film thickness associated with cryogenic fluids

The feasibility of measuring elastohydrodynamic (EHD) films as formed with a cryogenic (LN2) fluid is evaluated. Modifications were made to an existing twin disk EHD apparatus to allow for disk lubrication with liquid nitrogen. This disk apparatus is equipped with an X-ray system for measuring the thickness of any lubricant film that is formed between the disks. Several film thickness experiments were conducted with the apparatus which indicate that good lubrication films are filmed with LN2. In addition to the film thickness studies, failure analyses of three bearings were conducted. The HPOTP turbine end bearings had experienced axial loads of 36,000 to 44,000 N (8,000 to 10,000 lb). High continuous radial loads were also experienced, which were most likely caused by thermal growth of the inner race. The resulting high internal loads caused race spalling and ball wear to occur.

Kannel, J. W.↗

NASA NTRS1987

Contingency support using adaptive telemetry extractor and expert system technologies

The 'telemetry analysis logic for operations support' prototype system constitutes an expert system that is charged with contingency planning for the NASA Hubble Space Telescope (HST); this system has demonstrated the feasibility of using an adaptive telemetry extractor/reformatter that is integrated with an expert system. A test case generated by a simulator has demonstrated the reduction of the time required for analysis of a complex series of failures to a few minutes, from the hour usually required. The HST's telemetry extractor will be able to read real-time engineering telemetry streams and disk-based data. Telemetry format changes will be handled almost instantaneously.

Bryant, Thomas↗

NASA NTRS1978

Lubrication and failure mechanisms of graphite fluoride films

An optical microscope, equipped with a vertical illuminator and two polaroid filters (one rotatable), was used to visually study 440C HT steel surfaces lubricated with rubbed graphite fluoride films. Friction and wear results were compared to visual observations as a function of sliding distance for films applied to three surface finishes - polished, sanded, and sand-blasted. In general, the lubricating process was one of initial deformation or wear of metallic asperities into flat plateaus and then the formation of thin, layer-like, dynamic films which sheared between the flats and eventually flowed through the contact area. Failure was due to depletion of the graphite fluoride with the subsequent formation of excessive powdery metallic debris that formed a heavy, powdery film on both the rider and disk surfaces.

Fusaro, R. L.↗

NASA NTRS1994

UIT: Ultraviolet surface photometry of the spiral galaxy M74 (NGC 628)

Ultraviolet photometry, obtained from Ultraviolet Imaging Telescope (UIT) images at 1520 A (far-UV; magnitudes m(152)) and 2490 A (near-UV; magnitudes m(249)), of the spiral galaxy M74 (NGC 628) is compared with H-alpha, R, V, and B surface photometry and with models. M74's surface brightness profiles have a central peak with an exponential falloff; the exponential scale lengths of the profiles increase with decreasing wavelength for the broad-band images. The slope of the continuum-subtracted H-alpha profile is intermediate between those of far-UV and near-UV profiles, consistent with the related origins of H-alpha and UV emission in extreme Population I material. M74's color profiles all become bluer with increasing radius. The (m(152) - m(249)) color as measured by UIT averages near 0.0 (the color of an A0 star) over the central 20 sec radius and decreases from approximately -0.2 to approximately -0.4 from 20 sec to 200 sec. The spiral arms are the dominant component of the surface photometry colors; interarm regions are slightly redder. In the UV, M74's nuclear region resembles its disk/spiral arm material in colors and morphology, unlike galaxies such as M81. No UV 'bulge' is apparent. The m(152) - m(249) colors and models of M74's central region clearly demonstrate that there is no significant population of O or B stars present in the central 10 sec. M74's UV morphology and (m(152) - m(249)) color profiles are similar to those of M33, although M74 is approximately 0.5 mag redder. M81 has a smooth UV bulge which is much redder than the nuclear regions of M74 and M33. M74 is approximately 0.4 mag bluer than M81 in its outer disk, although M81 has bright UV sources only in spiral arms more than 5 kpc from its center. We investigate possible explanations for the color profiles of the galaxies and the differences among the galaxies: abundances; reddening due to internal dust; interplanetary magnetic field (IMF) variations, and the history of formation of the dominant generations of stars. Abundance and IMF variations do not produce large enough m(152) - m(249) or UV - V color differences. Comparing model UV/optical colors with those of M74 shows that M74's disk has undergone significant star formation over the past 500 Myr, and that either the star-formation history or the extinction varies systematically across M74's disk. Comparison of M74, M33, and M81 (UV - V) colors shows that M74 colors range from the bluest of M33's colors to the bluest of M81's. The failure of reddening models to cover the range of colors, and the known abundance range in such material, leads to the conclusion that star-formation history varies significantly as a function of radius in these galaxies, and that such variation is required to explain the range of colors observed in M74, M33, and M81.

Cornett, Robert H.↗

NASA NTRS1999

Combination Space Station Handrail Clamp and Pointing Device

A device for attaching an experiment carrier to a space station handrail is provided. The device has two major components, a clamping mechanism for attachment to a space station handrail, and a pointing carrier on which an experiment package can be mounted and oriented. The handrail clamp uses an overcenter mechanism and the carrier mechanism uses an adjustable preload ball and socket for carrier positioning. The handrail clamp uses a stack of disk springs to provide a spring loaded button. This configuration provides consistent clamping force over a range of possible handrail thicknesses. Three load points are incorporated in the clamping mechanism thereby spreading the clamping load onto three separate points on the handrail. A four bar linkage is used to provide for a single actuation lever for all three load points. For additional safety, a secondary lock consisting of a capture plate and push lock keeps the clamp attached to the handrail in the event of main clamp failure. For the carrier positioning mechanism, a ball in a spring loaded socket uses friction to provide locking torque; however. the ball and socket are torque limited so that the ball ran slip under kick loads (125 pounds or greater). A lead screw attached to disk spring stacks is used to provide an adjustable spring force on the socket. A locking knob is attached to the lead screw to allow for hand manipulation of the lead screw.

Hughes, Stephen J.↗

NASA NTRS1974

Rotor burst protection program: Statistics on aircraft gas turbine engine rotor failures that occurred in US commercial aviation during 1972

Based on FAA data, results are presented that establish (1) the incidence of rotor failure, (2) the type of fragments generated, (3) whether or not these fragments were contained, (4) the causes of failure, (5) where in the engine failure occurred, (6) what engines were affected and (7) what flight conditions prevailed at failure. The rate of uncontained rotor burst was considered to be significantly high. Blade fragments were generated in 95% of the rotor bursts, 20% of which were uncontained. Although fewer disk and rim fragment bursts occurred, none were contained.

Delucia, R. A.↗

NASA NTRS1989

Failure processes within ceramic coatings at high temperatures

Plasma sprayed coatings have a complex structure which is produced by the overlaying of many molten or semi-molten particles in the diameter range of 20 to 120 microns. The failure behavior of coatings has been characterized by using acoustic emission (AE) methodology. Coatings of NiCrAlY bond coat with a zirconia-12 wt pct yttria overlay were applied to disk-shaped specimens of U-700 alloy. A waveguide of 1-mm diameter platinum was TlG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150 C and the AE monitored. Analyses have been carried out with the aim of establishing parameters which are related to the crack size population. These studies have been used to postulate types of cracking mechanisms which may occur in plasma sprayed coatings during thermal cycling. It is shown that microcracking gave rise to a large amount of AE. However, this coating still survived more thermal cycles than a coating which exhibited macrocracking events.

Berndt, Christopher↗

NASA NTRS1986

Advanced Gas Turbine (AGT) Technology Project

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and analytical studies comprised AGT 100 activities during the 1985 year. Ten experimental assemblies (builds) were evaluated using two engines. Accrued operating time was 120 hr of burning and 170 hr total, bringing cumulative total operating time to 395 hr, all devoid of major failures. Tests identified the generator seals as the primary working fluid leakage sources. Power transfer clutch operation was demonstrated. An alpha SiC gasifier rotor engine test resulted in blade tip failures. Recurring case vibration and shaft whip have limited gasifier shaft speeds to 84%. Ceramic components successfully engine tested now include the SiC scroll assembly, Si3N3 turbine rotor, combustor assembly, regenerator disk bulkhead, turbine vanes, piston rings, and couplings. A compressor shroud design change to reduce heat recirculation back to the inlet was executed. Ceramic components activity continues to focus on the development of state-of-the-art material strength characteristics in full-scale engine hardware. Fiber reinforced glass-ceramic composite turbine (inner) backplates were fabricated by Corning Glass Works. The BMAS/III material performed well in engine testing. Backplates of MAS material have not been engine tested.

Source record↗

NASA NTRS2006

Effectiveness of Shot Peening In Suppressing Fatigue Cracking At Non-Metallic Inclusions In Udimet(Registered Trademark)720

The fatigue lives of modern powder metallurgy disk alloys can be reduced over an order of magnitude by cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens with and without shot peened test sections at 427 C and 650 C. The low cycle fatigue lives and failure initiation sites varied as functions of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with the introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. These inclusions reduced fatigue life by up to 100X, when compared to lives of material without inclusions residing at specimen surface. Large inclusions produced the greatest reductions in life for tests at low strain ranges and high strain ratios. Shot peening improved life in many cases by reducing the most severe effects of inclusions.

Barrie, Robert L.↗