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At least 109 records · Page 6

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NASA NTRS2012

Simulation of Oxygen Disintegration and Mixing With Hydrogen or Helium at Supercritical Pressure

The simulation of high-pressure turbulent flows, where the pressure, p, is larger than the critical value, p(sub c), for the species under consideration, is relevant to a wide array of propulsion systems, e.g. gas turbine, diesel, and liquid rocket engines. Most turbulence models, however, have been developed for atmospheric-p turbulent flows. The difference between atmospheric-p and supercritical-p turbulence is that, in the former situation, the coupling between dynamics and thermodynamics is moderate to negligible, but for the latter it is very significant, and can dominate the flow characteristics. The reason for this stems from the mathematical form of the equation of state (EOS), which is the perfect-gas EOS in the former case, and the real-gas EOS in the latter case. For flows at supercritical pressure, p, the large eddy simulation (LES) equations consist of the differential conservation equations coupled with a real-gas EOS. The equations use transport properties that depend on the thermodynamic variables. Compared to previous LES models, the differential equations contain not only the subgrid scale (SGS) fluxes, but also new SGS terms, each denoted as a correction. These additional terms, typically assumed null for atmospheric pressure flows, stem from filtering the differential governing equations, and represent differences between a filtered term and the same term computed as a function of the filtered flow field. In particular, the energy equation contains a heat-flux correction (q-correction) that is the difference between the filtered divergence of the heat flux and the divergence of the heat flux computed as a function of the filtered flow field. In a previous study, there was only partial success in modeling the q-correction term, but in this innovation, success has been achieved by using a different modeling approach. This analysis, based on a temporal mixing layer Direct Numerical Simulation database, shows that the focus in modeling the q-correction should be on reconstructing the primitive variable gradients rather than their coefficients, and proposes the approximate deconvolution model (ADM) as an effective means of flow field reconstruction for LES heat flux calculation. Further, results for a study conducted for temporal mixing layers initially containing oxygen in the lower stream, and hydrogen or helium in the upper stream, show that, for any LES, including SGS-flux models (constant-coefficient Gradient or Scale-Similarity models, dynamic-coefficient Smagorinsky/Yoshizawa or mixed Smagorinsky/Yoshizawa/Gradient models), the inclusion of the q-correction in the LES leads to the theoretical maximum reduction of the SGS heat-flux difference. The remaining error in modeling this new subgrid term is thus irreducible.

Bellan, Josette↗

NASA NTRS1983

Evaporation and combustion of sprays

A description is provided of recent spray evaporation and combustion models, taking into account turbulent two- and three-dimensional spray processes found in furnaces, gas turbine combustors, and internal combustion engines. Within the class of spray models of interest, two major categories are distinguished, including locally homogeneous flow (LHF) models and separated flow (SF) models. SF models are of the greatest practical importance, but LHF models have distinct advantages in some cases. Attention is also given to recent progress on modeling interactions between drops and the flow in both dilute and dense sprays, involving sprays having low and high liquid volume fractions, respectively.

Faeth, G. M.↗

NASA NTRS1986

Thermal barrier coating life prediction model development

The objective of this program is to establish a methodology to predict Thermal Barrier Coating (TBC) life on gas turbine engine components. The approach involves experimental life measurement coupled with analytical modeling of relevant degradation modes. The coating being studied is a flight qualified two layer system, designated PWA 264, consisting of a nominal ten mil layer of seven percent yttria partially stabilized zirconia plasma deposited over a nominal five mil layer of low pressure plasma deposited NiCoCrAlY. Thermal barrier coating degradation modes being investigated include: thermomechanical fatigue, oxidation, erosion, hot corrosion, and foreign object damage.

Demasi, J. T.↗

NASA NTRS2002

Ceramic Inclusions In Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially as the material chosen for turbine disks. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that arise from the powder atomization process. These inclusions can have potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they usually don't reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where a known population of ceramic particles, whose composition and morphology are designed to mimic the 'natural' inclusions, are added to the precursor powder. Surface connected inclusions have been found to have a particularly large detrimental effect on fatigue life, therefore the volume of ceramic 'seeds' added is calculated to ensure that a minimum number will occur on the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface and embedded cross-sectional areas were needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macro slices from extrusions and forgings. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions.

Bonacuse, Pete↗

NASA NTRS2001

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗

NASA NTRS1989

Thermal barrier coating life prediction model development, phase 1

The objective of this program was to establish a methodology to predict thermal barrier coating (TBC) life on gas turbine engine components. The approach involved experimental life measurement coupled with analytical modeling of relevant degradation modes. Evaluation of experimental and flight service components indicate the predominant failure mode to be thermomechanical spallation of the ceramic coating layer resulting from propagation of a dominant near interface crack. Examination of fractionally exposed specimens indicated that dominant crack formation results from progressive structural damage in the form of subcritical microcrack link-up. Tests conducted to isolate important life drivers have shown MCrAlY oxidation to significantly affect the rate of damage accumulation. Mechanical property testing has shown the plasma deposited ceramic to exhibit a non-linear stress-strain response, creep and fatigue. The fatigue based life prediction model developed accounts for the unusual ceramic behavior and also incorporates an experimentally determined oxide rate model. The model predicts the growth of this oxide scale to influence the intensity of the mechanic driving force, resulting from cyclic strains and stresses caused by thermally induced and externally imposed mechanical loads.

Demasi, Jeanine T.↗

DOE OSTI2024

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine

Modifying fossil-fueled industrial gas turbines to utilize low or zero-carbon fuels, such as hydrogen or hydrogen-natural gas blends, is a complex endeavor. The successful implementation of this technology hinges on three key design criteria: (1) developing new fuel injectors capable of efficiently burning alternative fuels, (2) ensuring manufacturability to meet cost and time-to-market goals, and (3) achieving component durability in the demanding environment of an operating gas turbine. Additive manufacturing (AM) accelerates product development, yet concerns persist regarding the durability of parts with rough AM surfaces. A fully experimental approach to quantify the fatigue performance of rough AM microstructures is both costly and labor-intensive. To address this, ORNL and Solar Turbines Incorporated (Solar) employed a crystal plasticity finite element (CPFE) model to identify the factors influencing AM surface fatigue behavior. These CPFE findings, combined with targeted experimental data, were used to develop a computationally efficient surrogate model suitable for assessing the lifespan of gas turbine engine components.

08 HYDROGEN↗

NASA NTRS1978

Computer Program for the Design and Off-Design Performance of Turbojet and Turbofan Engine Cycles

The rapid computer program is designed to be run in a stand-alone mode or operated within a larger program. The computation is based on a simplified one-dimensional gas turbine cycle. Each component in the engine is modeled thermo-dynamically. The component efficiencies used in the thermodynamic modeling are scaled for the off-design conditions from input design point values using empirical trends which are included in the computer code. The engine cycle program is capable of producing reasonable engine performance prediction with a minimum of computer execute time. The current computer execute time on the IBM 360/67 for one Mach number, one altitude, and one power setting is about 0.1 seconds. about 0.1 seconds. The principal assumption used in the calculation is that the compressor is operated along a line of maximum adiabatic efficiency on the compressor map. The fluid properties are computed for the combustion mixture, but dissociation is not included. The procedure included in the program is only for the combustion of JP-4, methane, or hydrogen.

Morris, S. J.↗

NASA NTRS1993

An overview of elevated temperature damage mechanisms and fatigue behavior of a unidirectional SCS-6/Ti-15-3 composite

The fatigue behavior of a unidirectionally reinforced titanium matrix composite (TMC), SiC/Ti-15-3, was thoroughly characterized to support life prediction modeling of advanced TMC disks designed for gas turbine engine applications. The results of this coupon-level experimental investigation are reviewed. On a stress basis, the isothermal fatigue behavior of the (0 deg) TMC revealed significant improvements over the unreinforced matrix. In contrast, the (90 deg) TMC exhibited degraded properties and lives for similar comparisons. This was attributed to the weak fiber/matrix interfacial bond. Encasing the (0 deg) TMC with a Ti-15-3 case did not affect isothermal fatigue lives at higher strain levels. However, at lower strain levels, rapid initiation and propagation of large fatigue cracks in the case degraded the fatigue lives. Thermomechanical fatigue (TMF) lives were significantly reduced for the (0 deg) TMC when compared to isothermal lives. At high strains, in-phase TMF produced extremely short lives. This degradation was attributed to fiber overload failures brought about by stress relaxation in the matrix. At low strains, out-of-phase TMF conditions became life limiting. Environment-assisted surface cracking was found to accelerate fatigue failure. This produced extensive matrix damage with minimal fiber damage. For the (90 deg) TMC, TMF conditions did not promote an additional degradation in cyclic life beyond that observed under isothermal conditions.

Castelli, Michael G.↗

NASA NTRS2006

Experimental and Numerical Characterization of Transient Insertion of Heat Flux Gages in a Cylindrical Black Body Cavity at 1100 C

Initial transient thermal models have been developed to simulate a heat flux gage calibration process capable of generating high heat flux levels of interest to reciprocating and gas turbine engine industries as well as the aerospace industry. These transient models are based on existing, experimentally validated, steady state models of the cylindrical blackbody calibration system. The steady state models were modified to include insertion of a heat flux gage into the hot zone of the calibration system and time varying electrical current passing through the resistance heated blackbody. Heat fluxes computed using the initial transient models were compared to experimental measurements. The calculated and measured transient heat fluxes were within 5% indicating that the major physical phenomena in the transient calibration had been captured by the models. The predicted and measured transient heat fluxes were also compared at two different gage insertion depths. These results indicated that there is an optimum insertion position which maximizes heat flux and minimizes cavity disturbance.

Abdelmessih, A. N.↗

DOE OSTI2025

Computational materials reliability assessment of hydrogen fueled gas turbine power generation engines

The use of blended fuel sources in land based gas turbine engines drives variations in the resulting operational profile (temperatures and pressures) which can impact engine reliability. Furthermore, variability in the manufacture of components affects the resulting microstructure which directly impacts material performance and reliability. Currently, data-driven models are typically used for maintaining and inspecting fleets of engines. Without explicitly capturing material and operational sources of variability conservatism must be used in developing component-level reliability models. Therefore, there exists an opportunity to use information from materials-scale physics models to better inform reliability modeling and reduce conservatism; the impact is more cost-efficient operation and maintenance of current and future fleets. Specifically, this work establishes a computational framework for evaluating the probabilistic high temperature creep performance of hot-section Ni-based superalloys where uncertainty comes from both microstructural and operational variability. A novel high-fidelity physics model which phenomenologically captures grain-boundary sensitive phenomena has been established. A probabilistic calibration procedure was used to calibrate the model and capture uncertainty in the parameterized model coefficients. A design of experiments methodology was established for identifying informative microstructural digital representations for suitable for forward model evaluation. Results show that training a machine-learning surrogate using this design criteria outperforms random selection of microstructural representations. Finally, two surrogate models were developed: (1) a deterministic surrogate model which predicts the local field response given microstructure, constitutive model parameters, and operating conditions (stress, temperature) and (2) a probabilistic model, where uncertainty comes from constitutive law uncertainty, built using denoising diffusion probabilistic models which samples responses given (1) microstructure and (2) operating conditions. These surrogate models enable partner Siemens Energy to rapidly perform UQ analysis specific to creep deformation across a range of microstructures and operating conditions. The impact is that these ML and physics codes can be used to establish more advanced reliability models for the inspection, servicing, and maintenance of land based gas turbine engines.

36 MATERIALS SCIENCE↗

NASA NTRS1977

Current status of droplet and liquid combustion

The present understanding of spray combustion in rocket engine, gas turbine, Diesel engine and industrial furnace applications is reviewed. In some cases, spray combustion can be modeled by ignoring the details of spray evaporation and treating the system as a gaseous diffusion flame; however, in many circumstances, this simplification is not adequate and turbulent two-phase flow must be considered. The behavior of individual droplets is a necessary component of two-phase models and recent work on transient droplet evaporation, ignition and combustion is considered, along with a discussion of important simplifying assumptions involved with modeling these processes. Methods of modeling spray evaporation and combustion processes are also discussed including: one-dimensional models for rocket engine and prevaporized combustion systems, lumped zone models (utilizing well-stirred reactor and plug flow regions) for gas turbine and furnace systems, locally homogeneous turbulent models, and two-phase models. The review highlights the need for improved injector characterization methods, more information of droplet transport characteristics in turbulent flow and continued development of more complete two-phase turbulent models

Faeth, G. M.↗

NASA NTRS1977

Current status of droplet and liquid combustion

The present understanding of spray combustion in rocket engine, gas turbine, Diesel engine and industrial furnace applications is reviewed. In some cases, spray combustion can be modeled by ignoring the details of spray evaporation and treating the system in the same manner as a gaseous diffusion flame; however, in many circumstances, this type of simplification is not adequate and the turbulent two-phase flow must be considered. The behavior of individual droplets is a necessary component of two-phase models and recent work on transient droplet evaporation, ignition and combustion is considered, along with a discussion of important simplifying assumptions involved with modeling these processes. Methods of modeling spray evaporation and combustion processes are also discussed including: one-dimensional models for rocket engine and prevaporized combustion systems, lumped zone models (utilizing well-stirred reactor and plug flow regions) for gas turbine and furnace systems, locally homogeneous turbulent models, and two-phase models. The review highlights the need for improved injector characterization methods, more information of droplet transport characteristics in turbulent flow and continued development of more complete two-phase turbulent models.

Faeth, G. M.↗

NASA NTRS2007

Effect of Insertion of a Heat Flux Gage into a High Temperature Cylindrical Blackbody Cavity on the Gage

Detailed transient thermal models have been developed to simulate a heat flux gage calibration process capable of generating high heat flux levels. These heat flux levels are of interest to the reciprocating and gas turbine engine industries as well as the aerospace industry. The transient models are based on existing, experimentally validated steady state models of a cylindrical blackbody calibration system. The steady state models were modified to include insertion of a heat flux gage into the hot zone of the calibration system, time-varying electrical current that passes through the resistance heated blackbody, and the resulting heating of the heat flux gage. Heat fluxes computed using detailed transient models were compared to experimental measurements. The calculated and measured transient heat fluxes agreed to within 2 percent, indicating that the models had captured the physical phenomena in the transient calibration. The predicted and measured transient heat fluxes were also compared for two different blackbody configurations. The effect of convection on the blackbody extension was evaluated and found to be a minor factor.

Abdelmessih, Amanie N.↗

NASA NTRS2005

Object-Oriented Version of Glenn-HT Code Released: Glenn-HT2000

NASA Glenn Research Center s General Multi-Block Navier-Stokes Convective Heat Transfer Code (Glenn-HT) has been used extensively to predict heat transfer and fluid flow for a variety of steady gas turbine engine problems. Efforts have focused on turbine heat transfer, where computations have modeled tip clearance, internal coolant, and film cooling flows. Excellent agreement has been achieved for a variety of experimental test cases, and results have been published in over 40 technical publications. The code is available to U.S. industry and has been used by several domestic gas turbine engine companies. The following figure shows a typical flow solution from the Glenn-HT code for a film-cooled turbine blade.

Heidmann, James D.↗

NASA NTRS1991

Thermal barrier coating life prediction model development, phase 2

The objective of this program was to generate a life prediction model for electron-beam-physical vapor deposited (EB-PVD) zirconia thermal barrier coating (TBC) on gas turbine engine components. Specific activities involved in development of the EB-PVD life prediction model included measurement of EB-PVD ceramic physical and mechanical properties and adherence strength, measurement of the thermally grown oxide (TGO) growth kinetics, generation of quantitative cyclic thermal spallation life data, and development of a spallation life prediction model. Life data useful for model development was obtained by exposing instrumented, EB-PVD ceramic coated cylindrical specimens in a jet fueled burner rig. Monotonic compression and tensile mechanical tests and physical property tests were conducted to obtain the EB-PVD ceramic behavior required for burner rig specimen analysis. As part of that effort, a nonlinear constitutive model was developed for the EB-PVD ceramic. Spallation failure of the EB-PVD TBC system consistently occurred at the TGO-metal interface. Calculated out-of-plane stresses were a small fraction of that required to statically fail the TGO. Thus, EB-PVD spallation was attributed to the interfacial cracking caused by in-plane TGO strains. Since TGO mechanical properties were not measured in this program, calculation of the burner rig specimen TGO in-plane strains was performed by using alumina properties. A life model based on maximum in-plane TGO tensile mechanical strain and TGO thickness correlated the burner rig specimen EB-PVD ceramic spallation lives within a factor of about plus or minus 2X.

Meier, Susan Manning↗

NASA NTRS1977

The influence of the inlet duct contour on forward radiated fan noise

Measurements have been obtained to determine the extent to which the shape of the inlet duct affects the directivity pattern of forward radiated noise from aircraft gas turbine engines. The test program was conducted using a model fan to which were attached any of three inlet ducts with each designed to cause a particular noise directivity pattern. Existing information on the effects of wave refraction in inlet-type flow fields was used to design the duct contours. Results indicated that the shape of the inlet duct strongly influenced the radiated noise field but that wave refraction was not the dominant factor in controlling the noise directivity pattern.

Sloan, D.↗

NASA NTRS1980

Performance characteristics of point-focusing distributed-receiver solar Brayton systems

Due to variations in solar insolation, it may be necessary or desirable to operate solar energy systems continuously in off-design conditions. Design of solar energy systems should maximize system efficiency at the design point and throughout the range of operational solar insolation. The solar power system considered in this study consists of a point-focusing concentrator, a cavity receiver, an open cycle gas turbine engine, and a heat regenerator. A computer simulation model was developed to predict off-design system performance. Results showing system efficiency and associated subsystems interface requirements are presented for various turbine inlet temperatures and engine speeds.

El Gabalawi, N.↗