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Blade-to-hub mounting concept assures excellent alignment integrity and results in elimination of some welding problems associated with designs. With this design, if rework is required, blade removal and replacement may be readily accomplished without damage to blade positioning media on the wheel hub.
Two sixty-foot, low-cost, wood composite blades for service on 200 kW Mod-OA wind turbines were constructed. The blades were constructed of epoxy resin-bonded Douglas fir veneers for the leading edge sections, and paper honeycombcored, birch plywood faced panels for the afterbody sections. The blades were joined to the wind turbine hub by epoxy resin-bonded steel load take-off studs embedded into the root end of the blades. The blades were installed on the 200 kW Mod-OA wind turbine facility at Kahuku, Hawaii, The blades completed nearly 8,000 hours of operation over an 18 month period at an average power of 150 kW prior to replacement with another set of wood composite blades. The blades were replaced because of a corrosion failure of the steel shank on one stud. Inspections showed that the wood composite structure remained in excellent condition.
The current practice in aerospace turbine engine maintenance is to remove components defined as life-limited parts after a fixed time, on the basis of a predetermined number of flight cycles. Under this schedule-based maintenance practice, the worst-case usage scenario is used to determine the usable life of the component. As shown, this practice often requires removing a part before its useful life is fully consumed, thus leading to higher maintenance cost. To address this issue, the NASA Glenn Research Center, in a collaborative effort with Pratt & Whitney, has developed a generic modular toolset that uses data-mining technology to parameterize life usage models for maintenance purposes. The toolset enables a "condition-based" maintenance approach, where parts are removed on the basis of the cumulative history of the severity of operation they have experienced. The toolset uses data-mining technology to tune life-consumption models on the basis of operating and maintenance histories. The flight operating conditions, represented by measured variables within the engine, are correlated with repair records for the engines, generating a relationship between the operating condition of the part and its service life. As shown, with the condition-based maintenance approach, the lifelimited part is in service until its usable life is fully consumed. This approach will lower maintenance costs while maintaining the safety of the propulsion system. The toolset is a modular program that is easily customizable by users. First, appropriate parametric damage accumulation models, which will be functions of engine variables, must be defined. The tool then optimizes the models to match the historical data by computing an effective-cycle metric that reduces the unexplained variability in component life due to each damage mode by accounting for the variability in operational severity. The damage increment due to operating conditions experienced during each flight is used to compute the effective cycles and ultimately the replacement time. Utilities to handle data problems, such as gaps in the flight data records, are included in the toolset. The tool was demonstrated using the first stage, high-pressure turbine blade of the PW4077 engine (Pratt & Whitney, East Hartford, CT). The damage modes considered were thermomechanical fatigue and oxidation/erosion. Each PW4077 engine contains 82 first-stage, high-pressure turbine blades, and data from a fleet of engines were used to tune the life-consumption models. The models took into account not only measured variables within the engine, but also unmeasured variables such as engine health parameters that are affected by degradation of the engine due to aging. The tool proved effective at predicting the average number of blades scrapped over time due to each damage mode, per engine, given the operating history of the engine. The customizable tools are available to interested parties within the aerospace community.
The wood composite blades were fabricated by using epoxy resin-bonded laminates of Douglas fir veneers for the leading edge spar sections and honeycomb-cored birch plywood panels for the blade trailing edge or afterbody sections. The blade was joined to the wind turbine hub assembly by epoxy resin-bonded steel load take-off studs. The wood composite blades were installed in the Mod-OA wind turbine test facility at Kahuku, Hawaii. The wood composite blades have successfully completed high power (average of 150 kW) operations for an eighteen month period (nearly 8,000 hr) before replacement with another set of wood composite blades. The original set of blades was taken out of service because of the failure of the shank on one stud. An inspection of the blades at NASA-Lewis showed that the shank failure was caused by a high stress concentration at a corrosion pit on the shank fillet radius which resulted in fatigue stresses in excess of the endurance limit.
Polymer Matrix Composites (PMCs) offer lightweight and frequently low cost alternatives to other materials in many applications. High temperature PMCs are currently used in limited propulsion applications replacing metals. Yet in most cases, PMC propulsion applications are not in the direct engine flow path since particulate erosion degrades PMC component performance and therefore restricts their use in gas turbine engines. This paper compares two erosion resistant coatings (SANRES and SANPRES) on PMCs that are useful for both low and high temperature propulsion applications. Collaborating over a multi-year period, researchers at NASA Glenn Research Center, Allison Advanced Developed Company, and Rolls-Royce Corporation have optimized these coatings in terms of adhesion, surface roughness, and erosion resistance. Results are described for vigorous hot gas/particulate erosion rig and engine testing of uncoated and coated PMC fan bypass vanes from the AE 3007 regional jet gas turbine engine. Moreover, the structural durability of these coatings is described in long-term high cycle fatigue tests. Overall, both coatings performed well in all tests and will be considered for applications in both commercial and defense propulsion applications.
The Refan Program is aimed at a large reduction in aircraft approach and takeoff noise in the vicinity of airports caused by the JT3D-powered 707's and DC-8's and the JT8D-powered 727's, 737's and DC-9's. These aircraft represent a major part of the existing commercial fleet. The noise reductions can be achieved by engine and nacelle modifications in the form of aircraft retrofit kits. Engine turbomachinery noise is reduced by replacing the current two-stage fan with a larger single-stage fan and by nacelle acoustic treatment. Jet noise is reduced by the reduction on jet velocity caused by additional turbine work extraction to drive the larger bypass fan. The predicted net effect of these modifications on installed performance is large noise reductions on both approach and takeoff, increased takeoff thrust, decreased takeoff field length, and maintained or improved aircraft range depending on the amount of acoustic treatment included. The Refan Program is being conducted in two phases under contracts with one engine and two airframe companies. Results of the Phase I work are summarized in this report which describes the refan nacelle configurations studied, the airplane modifications required to install the nacelles, and the resulting airplane performance and noise reductions predicted for all five aircraft.
Engine manufacturers are continually attempting to improve the performance and efficiency of internal combustion engines. Usually they raise the operating temperature or reduce the cooling air requirement for the hot section turbine components. However, the success of these attempts depends on finding materials that are lightweight, are strong, and can withstand high temperatures. Ceramics are among the top candidate materials considered for such harsh applications. They hold low-density, high-temperature strength, and thermal conductivity, and they are undergoing investigation as potential materials for replacing nickel-base alloys and superalloys that are currently used for engine hot-section components. Ceramic structures can withstand higher operating temperatures and a harsh combustion environment. In addition, their low densities relative to metals help reduce component mass. The long-term objectives of the High Temperature Propulsion Components (HOTPC) Project are to develop manufacturing technology, thermal and environmental barrier coatings (TBC/EBC), and the analytical modeling capability to predict thermomechanical stresses in minimally cooled silicon nitride turbine nozzle vanes under simulated engine conditions. Two- and three-dimensional finite element analyses with TBC were conducted at the NASA Glenn Research Center. Nondestructive evaluation was used to determine processing defects. The study included conducting preliminary parametric analytical runs of heat transfer and stress analyses under steady-state conditions to demonstrate the feasibility of using cooled Si3N4 parts for turbine applications. The influence of cooling-channel shapes (such as circular, square, and ascending-order cooling channels) on cooling efficiency and thermal stresses was investigated. Temperature distributions were generated for all cases considered under both cooling and no-cooling conditions, with air being the cooling medium. The table shows the magnitude of the maximum and minimum temperature obtained for the plates under air cooling. Each channel's cross-sectional shape delivered a different temperature; however, the two-dimensional analyses for circular and square or equal-side rectangular holes produced close results. Moreover, the model of the panel with ascending order cooling channels experienced the lowest temperature. A difference of near 260 C was found among the three cooling-hole configurations investigated. The ascending-order cooling channels arrangement showed superior performance by attaining the lowest temperature (1077 C) in comparison to the circular (1379 C) and square (1343 C) channels for the same cooling-hole size. This indicates that the panel with ascending-order cooling channels is the most suitable configuration regardless of the complexity involved in its manufacture. More details pertaining to this study are reported.
The neural network and regression methods of NASA Glenn Research Center s COMETBOARDS design optimization testbed were used to generate approximate analysis and design models for a subsonic aircraft operating at Mach 0.85 cruise speed. The analytical model is defined by nine design variables: wing aspect ratio, engine thrust, wing area, sweep angle, chord-thickness ratio, turbine temperature, pressure ratio, bypass ratio, fan pressure; and eight response parameters: weight, landing velocity, takeoff and landing field lengths, approach thrust, overall efficiency, and compressor pressure and temperature. The variables were adjusted to optimally balance the engines to the airframe. The solution strategy included a sensitivity model and the soft analysis model. Researchers generated the sensitivity model by training the approximators to predict an optimum design. The trained neural network predicted all response variables, within 5-percent error. This was reduced to 1 percent by the regression method. The soft analysis model was developed to replace aircraft analysis as the reanalyzer in design optimization. Soft models have been generated for a neural network method, a regression method, and a hybrid method obtained by combining the approximators. The performance of the models is graphed for aircraft weight versus thrust as well as for wing area and turbine temperature. The regression method followed the analytical solution with little error. The neural network exhibited 5-percent maximum error over all parameters. Performance of the hybrid method was intermediate in comparison to the individual approximators. Error in the response variable is smaller than that shown in the figure because of a distortion scale factor. The overall performance of the approximators was considered to be satisfactory because aircraft analysis with NASA Langley Research Center s FLOPS (Flight Optimization System) code is a synthesis of diverse disciplines: weight estimation, aerodynamic analysis, engine cycle analysis, propulsion data interpolation, mission performance, airfield length for landing and takeoff, noise footprint, and others.
The potential demand for space processed turbine blades, and the dollar benefits to be derived from this technology were analyzed. It was found that an adequate demand to justify space processed blades will exist. The cost benefits per blade for replacements in existing aircraft is estimated to be $997.50 per blade, and for new aircraft the savings per blade would be over $21,000.00.
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.
Active magnetic bearings provide revolutionary advantages for gas turbine engine rotor support. These advantages include tremendously improved vibration and stability characteristics, reduced power loss, improved reliability, fault-tolerance, and greatly extended bearing service life. The marriage of these advantages with innovative structural network design and advanced materials utilization will permit major increases in thrust to weight performance and structural efficiency for future gas turbine engines. However, obtaining the maximum payoff requires two key ingredients. The first key ingredient is the use of modern magnetic bearing technologies such as innovative digital control techniques, high-density power electronics, high-density magnetic actuators, fault-tolerant system architecture, and electronic (sensorless) position estimation. This paper describes these technologies. The second key ingredient is to go beyond the simple replacement of rolling element bearings with magnetic bearings by incorporating magnetic bearings as an integral part of the overall engine design. This is analogous to the proper approach to designing with composites, whereby the designer tailors the geometry and load carrying function of the structural system or component for the composite instead of simply substituting composites in a design originally intended for metal material. This paper describes methodologies for the design integration of magnetic bearings in gas turbine engines.
Over the past several years the term oil-free turbomachinery has been used to describe a rotor support system for high speed turbomachinery that does not require oil for lubrication, damping, or cooling. The foundation technology for oil-free turbomachinery is the compliant foil bearing. This technology can replace the conventional rolling element bearings found in current engines. Two major benefits are realized with this technology. The primary benefit is the elimination of the oil lubrication system, accessory gearbox, tower shaft, and one turbine frame. These components account for 8 to 13 percent of the turbofan engine weight. The second benefit that compliant foil bearings offer to turbofan engines is the capability to operate at higher rotational speeds and shaft diameters. While traditional rolling element bearings have diminished life, reliability, and load capacity with increasing speeds, the foil bearing has a load capacity proportional to speed. The traditional applications for foil bearings have been in small, lightweight machines. However, recent advancements in the design and manufacturing of foil bearings have increased their potential size. An analysis, grounded in experimentally proven operation, is performed to assess the scalability of the modern foil bearing. This analysis was coupled to the requirements of civilian turbofan engines. The application of the foil bearing to larger, high bypass ratio engines nominally at the 120 kN (approx.25000 lb) thrust class has been examined. The application of this advanced technology to this system was found to reduce mission fuel burn by 3.05 percent.
The Automaton Rover for Extreme Environments (AREE) is a NASA Innovative Advanced Concept (NIAC) funded study focused on enabling long duration science on Venus by replacing vulnerable electronics with an entirely mechanical design. By utilizing high temperature alloys, the rover would survive on the surface of Venus for weeks if not months. The rover concept harvests wind energy using a turbine and stores it in a constant force spring. The mobility system would be guided by a mechanical computer and logic system, programed to carry out the mission. It would collect basic science data such as wind speed, temperature, and seismic events. Communicating the data back to Earth is the most challenging aspect of the system design with multiple options being explored in a trade: a simple electronic high temperature transponder, a retroreflector target or inscribing phonograph style records to be launched via a balloon to a high altitude drone capable of transmitting the data back to Earth. AREE is not only a new exciting in-situ rover concept, but also a paradigm shift to conducting in-situ science in extreme environments. Traditional extreme environment vehicles collect as many diverse data points as possible in the short period of time before system failure. AREE breaks that trend by exploring what can be done with only a few basic scientific measurements, but recorded over long periods of time. In addition to Venus, the concept can be useful in other extreme environments in the solar system including Mercury, Jupiter's radiation belts, the interiors of gas giants, the mantle of the Earth and volcanoes throughout the solar system.
The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.
Because grid generation can consume 70 percent of the total analysis time for a typical three-dimensional viscous flow simulation for a practical engineering device, payoffs from research and development could reduce costs and increase throughputs considerably. In this study, researchers at the NASA Glenn Research Center at Lewis Field developed a new hybrid grid approach with the advantages of flexibility, high-quality grids suitable for an accurate resolution of viscous regions, and a low memory requirement. These advantages will, in turn, reduce analysis time and increase accuracy. They result from an innovative combination of structured and unstructured grids to represent the geometry and the computation domain. The present approach makes use of the respective strengths of both the structured and unstructured grid methods, while minimizing their weaknesses. First, the Chimera grid generates high-quality, mostly orthogonal meshes around individual components. This process is flexible and can be done easily. Normally, these individual grids are required overlap each other so that the solution on one grid can communicate with another. However, when this communication is carried out via a nonconservative interpolation procedure, a spurious solution can result. Current research is aimed at entirely eliminating this undesired interpolation by directly replacing arbitrary grid overlapping with a nonstructured grid called a DRAGON grid, which uses the same set of conservation laws over the entire region, thus ensuring conservation everywhere. The DRAGON grid is shown for a typical film-cooled turbine vane with 33 holes and 3 plenum compartments. There are structured grids around each geometrical entity and unstructured grids connecting them. In fiscal year 1999, Glenn researchers developed and tested the three-dimensional DRAGON grid-generation tools. A flow solver suitable for the DRAGON grid has been developed, and a series of validation tests are underway.
The operating requirements established by NASA for the SSME were considerably more demanding than those for earlier rocket engines used in the military launch vehicles or Apollo program. The SSME, in order to achieve the high performance, low weight, long life, reusable objectives, embodied technical demands far in excess of its predecessor rocket engines. The requirements dictated the use of high combustion pressure and the staged combustion cycle which maximizes performance through total use of all propellants in the main combustion process. This approach presented a myriad of technical challenges for maximization of performance within attainable state of the art capabilities for operating pressures, operating temperatures and rotating machinery efficiencies. Controlling uniformity of the high pressure turbomachinery turbine temperature environment was a key challenge for thrust level and life capability demanding innovative engineering. New approaches in the design of the components were necessary to accommodate the multiple use, minimum maintenance objectives. Included were the use of line replaceable units to facilitate field maintenance automatic checkout and internal inspection capabilities.
An investigation was conducted to correlate the engine service performance of cast Vitallium turbine buckets with standard laboratory metallurgical data. Data were obtained from four I-40 turbine wheels of Timken alloy with cast Vitallium buckets. In order to accelerate bucket deterioration, the turbine wheels were subjected to 20-minute cycles consisting of 5 minutes at idle and 15 minutes at rated speed. A bucket broke on the first wheel during cycle 22 after 7 hours and 20 minutes. The broken bucket was replaced and during the third cycle after the replacement a second bucket broke after a total running time of 8 hours and 12 minutes, The first bucket failure on the second wheel occurred during cycle 29 after 9 hours and 28 minutes; no further failure occurred during 66 additional cycles. Total running time on this wheel was 31 hours and 40 minutes. The third wheel was run for 229 cycles (76 hr and 20 min, total running time) without a. failure. The fourth wheel was operated for 105 cycles (35 hr, total running time) without a failure. Examination of the bro?en buckets indicated that the failures were probably due to fatigue, Massive eutectic areas that existed near the trailing edge probably contributed to the low fatigue strength.
Because of the import status and essential nature of their use, cobalt, chromium, tantalum, and niobium were identified as strategic and critical in the aerospace industry. NASA's Conservation of Strategic Aerospace Materials (COSAM) program aims to reduce the need for strategic materials used in gas turbine engines. Technological thrusts in two major areas are under way to meet the primary objective of conserving the use of strategic materials in nickelbase superalloys. These thrusts consist of strategic element substitution and alternative material identification. The program emphasizes cooperative research teams involving NASA Lewis Research Center, universities, and industry. The adoption of refractory metals in nickel-base superalloys is summarized including their roles in mechanical strengthening and environmental resistance; current research activities under way in the COSAM Program are presented as well as research findings to date.