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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 127 records · Page 7

Development history of the Space Shuttle Main Engine

The development of the Space Shuttle Main Engine has provided a high performance, reusable component for the Space Transportation System. A discussion of how ground testing identified problems and their resolution paved the way for certification of the engine for flight. A launch summary and a discussion of launch anomalies are included. Continuing improvements and established overhaul criteria are described which will extend the operating life and allow each engine to be used efficiently.

Peterson, T. J.↗

Space shuttle main engine computed tomography applications

For the past two years the potential applications of computed tomography to the fabrication and overhaul of the Space Shuttle Main Engine were evaluated. Application tests were performed at various government and manufacturer facilities with equipment produced by four different manufacturers. The hardware scanned varied in size and complexity from a small temperature sensor and turbine blades to an assembled heat exchanger and main injector oxidizer inlet manifold. The evaluation of capabilities included the ability to identify and locate internal flaws, measure the depth of surface cracks, measure wall thickness, compare manifold design contours to actual part contours, perform automatic dimensional inspections, generate 3D computer models of actual parts, and image the relationship of the details in a complex assembly. The capabilities evaluated, with the exception of measuring the depth of surface flaws, demonstrated the existing and potential ability to perform many beneficial Space Shuttle Main Engine applications.

Sporny, Richard F.↗

Engine dynamic analysis with general nonlinear finite element codes

A general engine dynamic analysis as a standard design study computational tool is described for the prediction and understanding of complex engine dynamic behavior. Improved definition of engine dynamic response provides valuable information and insights leading to reduced maintenance and overhaul costs on existing engine configurations. Application of advanced engine dynamic simulation methods provides a considerable cost reduction in the development of new engine designs by eliminating some of the trial and error process done with engine hardware development.

Adams, M. L.↗

Communication: An important element of maintenance and repair

People from the airlines, the FAA, and the manufacturers have worked together in an effort to improve the Service Difficulty Reporting system. Their work to date is summarized as follows. - Goals were generalized into three broad work statements; (a) design a worldwide reporting system to provide safety alerts to aircraft operators, manufacturers, repair facilities, and regulatory authorities. (b) design a companion system to provide worldwide reliability experience. (c) overhaul regulatory requirements to be consistent with (a) and (b) to provide information necessary and useful for public consumption.

Aging Aircraft↗

Aging commuter aeroplanes: Fatigue evaluation and control methods

The risks associated with old aeroplanes arise in the main from the difficulty of obtaining support from the manufacturer and other skilled people, and from a general loss of reliability caused by wear and other deterioration. The loss of reliability is caused by two broad classes of problem. There are those problems which are self evident, and hazardous rather than catastrophic. These are the problem areas where characteristically there have been multiple overhauls, repairs, and replacements, and where aging really means the results of repair ineffectiveness that accumulates. The other class of problem is the insidious and potentially catastrophic class. It includes the progressive deterioration of items which are not maintained, and often cannot be maintained because the deterioration cannot be seen. It includes loss of physical properties in adhesives and other organic compounds, corrosion, and the response to repeated loads. This paper deals with a currently unnecessarily troublesome aspect of that response. The present working definition of "commuter aeroplanes" encompasses a wide range of aging types, from the Fairchild F27, through deHavilland Canada Twin Otters to the smaller twin engined Piper and Cessna models. It includes such types as the Lockheed 10, the Beech 18, and the Grumman Mallard. Although we must remain concerned about those types which have been certificated under a design standard or operational rule which embodies the elementary fail-safe concept and which have not been subjected to a subsequent structural audit, this paper is directed, in the first instance, towards types for which fatigue and damage tolerance evaluation was not required as a condition of certification. It will be seen, however, that the principles are robust enough for more general application.

Aging Aircraft↗

The NASA-OAST earth-to-orbit propulsion technology program - The action plan

The paper discusses the primary objective of the NASA-OAST earth-to-orbit (ETO) propulsion technology program, namely, to completely overhaul the nation's liquid rocket design and analysis capabilities which were found to be severely limited when used for the design and development of the Space Shuttle Main Engine (SSME). Meeting this objective is to provide a much sounder, very comprehensive technology base that will enable the cost-effective low-risk development, acquisition, and operation of high-performance, expendable, or reusable ETO propulsion systems. This in turn will enable the future development of space transportation system launch vehicles with greatly reduced life-cycle costs. Work is carried out in three major areas: combustion devices, turbomachinery, and controls and health management.

Escher, W. J. D.↗

Spur, helical, and spiral bevel transmission life modeling

A computer program, TLIFE, which estimates the life, dynamic capacity, and reliability of aircraft transmissions, is presented. The program enables comparisons of transmission service life at the design stage for optimization. A variety of transmissions may be analyzed including: spur, helical, and spiral bevel reductions as well as series combinations of these reductions. The basic spur and helical reductions include: single mesh, compound, and parallel path plus revert star and planetary gear trains. A variety of straddle and overhung bearing configurations on the gear shafts are possible as is the use of a ring gear for the output. The spiral bevel reductions include single and dual input drives with arbitrary shaft angles. The program is written in FORTRAN 77 and has been executed both in the personal computer DOS environment and on UNIX workstations. The analysis may be performed in either the SI metric or the English inch system of units. The reliability and life analysis is based on the two-parameter Weibull distribution lives of the component gears and bearings. The program output file describes the overall transmission and each constituent transmission, its components, and their locations, capacities, and loads. Primary output is the dynamic capacity and 90-percent reliability and mean lives of the unit transmissions and the overall system which can be used to estimate service overhaul frequency requirements. Two examples are presented to illustrate the information available for single element and series transmissions.

Savage, Michael↗

Problems with aging wiring in Naval aircraft

The Navy is experiencing a severe aircraft electrical wiring maintenance problem as a result of the extensive use of an aromatic polyimide insulation that is deteriorating at a rate that was unexpected when this wire was initially selected. This problem has significantly affected readiness, reliability, and safety and has greatly increased the cost of ownership of Naval aircraft. Failures in wire harnesses have exhibited arcing and burning that will propagate drastically, to the interruption of many electrical circuits from a fault initiated by the failure of deteriorating wires. There is an urgent need for a capability to schedule aircraft rewiring in an orderly manner with a logically derived determination of which aircraft have aged to the point of absolute necessity. Excessive maintenance was demonstrated to result from the accelerated aging due to the parameters of moisture, temperature, and strain that exist in the Naval Aircraft environment. Laboratory studies have demonstrated that MIL-W-81381 wire insulation when aged at high humidities followed the classical Arrhenius thermal aging relationship. In an extension of the project a multifactor formula was developed that is now capable of predicting life under varying conditions of these service parameters. An automated test system has also been developed to analyze the degree of deterioration that has occurred in wires taken from an aircraft in order to obtain an assessment of remaining life. Since it is both physically and financially impossible to replace the wiring in all the Navy's aircraft at once, this system will permit expedient scheduling so that those aircraft that are most probable to have wiring failure problems can be overhauled first.

Campbell, Frank J.↗

Quality optimization of thermally sprayed coatings produced by the JP-5000 (HVOF) gun using mathematical modeling

Currently, thermal barrier coatings (TBC) of gas-turbine blades and similar applications have centered around the use of zirconia as a protective coating for high thermal applications. The advantages of zirconia include low thermal conductivity and good thermal shock resistance. Thermally sprayed tungsten carbide hardface coatings are used for a wide range of applications spanning both the aerospace and other industrial markets. Major aircraft engine manufacturers and repair facilities use hardface coatings for original engine manufacture (OEM), as well as in the overhaul of critical engine components. The principle function of these coatings is to resist severe wear environments for such wear mechanisms as abrasion, adhesion, fretting, and erosion. The (JP-5000) thermal spray gun is the most advanced in the High Velocity Oxygen Fuel (HVOF) systems. Recently, it has received considerable attention because of its relative low cost and its production of quality coatings that challenge the very successful but yet very expensive Vacuum Plasma Spraying (VPS) system. The quality of thermal spray coatings is enhanced as porosity, oxidation, residual stress, and surface roughness are reduced or minimized. Higher densification, interfacial bonding strength, hardness and wear resistance of coating are desirable features for quality improvement.

Tawfik, Hazem↗

An ammonia monitor for the water industry

Following the emergence of the European Community as a unified trading and economic entity, the various member states are required to follow certain directives governing their social affairs. Many of these directives concern the quality of the air we breathe, and the water that we use for consumption or in industrial processes. In order to comply with these directives a major overhaul of the water industry in the UK was required. For example, in many coastal towns and resorts there has never been any formal sewage treatment since, traditionally, all waste was dumped at sea through outfall pipes. Because this is no longer acceptable, whole new treatment systems are required.

Brokenshire, J. L.↗

Advanced Technology Training System on Motor-Operated Valves

This paper describes how features from the field of Intelligent Tutoring Systems are applied to the Motor-Operated Valve (MOV) Advanced Technology Training System (ATTS). The MOV ATTS is a training system developed at Galaxy Scientific Corporation for the Central Research Institute of Electric Power Industry in Japan and the Electric Power Research Institute in the United States. The MOV ATTS combines traditional computer-based training approaches with system simulation, integrated expert systems, and student and expert modeling. The primary goal of the MOV ATTS is to reduce human errors that occur during MOV overhaul and repair. The MOV ATTS addresses this goal by providing basic operational information of the MOV, simulating MOV operation, providing troubleshooting practice of MOV failures, and tailoring this training to the needs of each individual student. The MOV ATTS integrates multiple expert models (functional and procedural) to provide advice and feedback to students. The integration also provides expert model validation support to developers. Student modeling is supported by two separate student models: one model registers and updates the student's current knowledge of basic MOV information, while another model logs the student's actions and errors during troubleshooting exercises. These two models are used to provide tailored feedback to the student during the MOV course.

Wiederholt, Bradley J.↗

Turbomachine Sealing

Designers and customers are demanding higher performance turbomachine systems that have long life between overhauls and satisfy the more restrictive environmental constraints. This overview provides sources of design data, numerical, and experimental results along with selected new seal configurations and static sealing challenges such as in the combustors. The following categories are presented: (1) Seal Rotordynamic Data Base (experimental analytical program at Texas A&M); (2) Secondary Flow Interactions (validation studies at CFDRC, Huntsville AL); (3) Contact Sealing (selected types with finger seal model); and (4) Environmental Constraints (emphasis on combustors).

Hendricks, Robert C.↗

The Strutjet Rocket Based Combined Cycle Engine

The multi stage chemical rocket has been established over many years as the propulsion System for space transportation vehicles, while, at the same time, there is increasing concern about its continued affordability and rather involved reusability. Two broad approaches to addressing this overall launch cost problem consist in one, the further development of the rocket motor, and two, the use of airbreathing propulsion to the maximum extent possible as a complement to the limited use of a conventional rocket. In both cases, a single-stage-to-orbit (SSTO) vehicle is considered a desirable goal. However, neither the "all-rocket" nor the "all-airbreathing" approach seems realizable and workable in practice without appreciable advances in materials and manufacturing. An affordable system must be reusable with minimal refurbishing on-ground, and large mean time between overhauls, and thus with high margins in design. It has been suggested that one may use different engine cycles, some rocket and others airbreathing, in a combination over a flight trajectory, but this approach does not lead to a converged solution with thrust-to-mass, specific impulse, and other performance and operational characteristics that can be obtained in the different engines. The reason is this type of engine is simply a combination of different engines with no commonality of gas flowpath or components, and therefore tends to have the deficiencies of each of the combined engines. A further development in this approach is a truly combined cycle that incorporates a series of cycles for different modes of propulsion along a flight path with multiple use of a set of components and an essentially single gas flowpath through the engine. This integrated approach is based on realizing the benefits of both a rocket engine and airbreathing engine in various combinations by a systematic functional integration of components in an engine class usually referred to as a rocket-based combined cycle (RBCC) engine. RBCC engines exhibit a high potential for lowering the operating cost of launching payloads into orbit. Two sources of cost reductions can be identified. First, RBCC powered vehicles require only 20% takeoff thrust compared to conventional rockets, thereby lowering the thrust requirements and the replacement cost of the engines. Second, due to the higher structural and thermal margins achievable with RBCC engines coupled with a higher degree of subsystem redundance lower maintenance and operating cost are obtainable.

Siebenhaar, A.↗

Space Shuttle Orbital Maneuvering Subsystem (OMS) Engine Propellant Leakage Ball-Valve Shaft Seals

Evidence of propellant leakage across ball-valve shaft seals has been noted during the disassembly of five flight engines and one test engine at the NASA Lyndon B. Johnson Space Center, White Sands Test Facility. Based on data collected during the disassembly of these five engines, the consequences of propellant leakage across the ball-valve shaft seals can be divided into four primary areas of concern: Damage to the ball-valve pinion shafts, damage to sleeved bearings inside the ball-valve and actuator assemblies, degradation of the synthetic rubber o-rings used in the actuator assemblies, and corrosion and degradation to the interior of the actuator assemblies. The exact time at which leakage across the ball-valve shaft seals occurs has not been determined, however, the leakage most likely occurs during engine firings when, depending on the specification used, ball-valve cavity pressures range as high as 453 to 550 psia. This potential pressure range for the ball-valve cavities greatly exceeds the acceptance leakage test pressure of 332 psia. Since redesign and replacement of the ball-valve shaft seals is unlikely, the near term solution to prevent damage that occurs from shaft-seal leakage is to implement a routine overhaul and maintenance program for engines in the fleet. Recommended repair, verification, and possible preventative maintenance measures are discussed in the paper.

Lueders, Kathy↗

What Has He Done For Me Lately?

I had a boss once who continually asked me what the purpose of my work was, who were my customers, and how was I keeping my customers informed about my team's work. At first I found these questions perplexing, as my customers should have known the answers. I had covered them in my monthly/quarterly reports or in my project meeting notes. Finally, I confronted him about his questions. He acknowledged that my customers had this information, but he was hearing some disturbing comments between when I submitted my reports, comments like, 'What has he done for me lately?' I decided to take this input to heart. My ideas about communications norms needed a major overhaul. The communication norms I was comfortable with were becoming outdated. I realized the written and verbal communications response time was suddenly being measured in days or minutes. People's perception of a project team based on monthly or quarterly meetings was no longer adequate. In the past, once the team's credibility was established it was hard to change. In a rapid-fire communications world, no news causes people to question what the team is doing to move the business/project ahead.

Cameron, W. Scott↗

Turbine Engine Clearance Control Systems: Current Practices and Future Directions

Improved blade tip sealing in the high pressure compressor (HPC) and high pressure turbine (HPT) can provide dramatic reductions in specific fuel consumption (SFC), time-on-wing, compressor stall margin, and engine efficiency as well as increased payload and mission range capabilities. Maintenance costs to overhaul large commercial gas turbine engines can easily exceed $1M. Engine removal from service is primarily due to spent exhaust gas temperature (EGT) margin caused mainly by the deterioration of HPT components. Increased blade tip clearance is a major factor in hot section component degradation. As engine designs continue to push the performance envelope with fewer parts and the market drives manufacturers to increase service life, the need for advanced sealing continues to grow. A review of aero gas turbine engine HPT performance degradation and the mechanisms that promote these losses are discussed. Benefits to the HPT due to improved clearance management are identified. Past and present sealing technologies are presented along with specifications for next generation engine clearance control systems.

Lattime, Scott B.↗

Package for Interactive Analysis of Line Emission (Analysis of UV-X-Ray High-Resolution Emission Spectra)

PINTofALE is an IDL based package to analyze high-resolution grating spectra. The first version was made available to the public on 3 February 2001. Since then we have carried out numerous changes, and the current release is version 1.5, released on 9 October 2002. The changes include upgrades to handle higher versions of IDL, the new version of the CHIANTI database (v4), major enhancements in user-friendliness, improved handling of response matrices, the ability to handle 24-bit color, access to the Atomic Plasma Emission Database (APED), and beta releases of Markov Chain Monte Carlo (MCMC) based DEM fitting routines. Plans for the future include: inclusion of MCMC techniques in the fitting programs, enhanced graphics capabilities, an overhaul of the line and continuum database structure, and bug fixes. In September 2002, we hired a data analyst (LiWei Lin) to work on PINTofALE. Mr.Lin is concentrating on incorporating MCMC as well as simpler Monte-Carlo techniques, fast RMF convolution, etc., into the code base, as well as reviewing the existing documentation and searching for bugs. A detailed description of the package, together with fairly detailed documentation, example walks-throughs, and downloadable tar files, are available on-line from http://hea-www. harvard.edu/PINTofALE/

Kashyap, Vinay↗

Engine Damage to a NASA DC-8-72 Airplane From a High-Altitude Encounter With a Diffuse Volcanic Ash Cloud

The National Aeronautics and Space Administration (NASA) DC-8 airborne sciences research airplane inadvertently flew through a diffuse volcanic ash cloud of the Mt. Hekla volcano in February 2000 during a flight from Edwards Air Force Base (Edwards, California) to Kiruna, Sweden. Although the ash plume was not visible to the flight crew, sensitive research experiments and instruments detected it. In-flight performance checks and postflight visual inspections revealed no damage to the airplane or engine first-stage fan blades; subsequent detailed examination of the engines revealed clogged turbine cooling air passages. The engines were removed and overhauled. This paper presents volcanic ash plume analysis, trajectory from satellites, analysis of ash particles collected in cabin air heat exchanger filters and removed from the engines, and data from onboard instruments and engine conditions.

Grindle, Thomas J.↗