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NASA NTRS2008

The Inception of OMA in the Development of Modal Testing Technology for Wind Turbines

Wind turbines are immense, flexible structures with aerodynamic forces acting on the rotating blades at harmonics of the turbine rotational frequency, which are comparable to the modal frequencies of the structure. Predicting and experimentally measuring the modal frequencies of wind turbines has been important to their successful design and operation. Performing modal tests on wind turbine structures over 100 meters tall is a substantial challenge, which has inspired innovative developments in modal test technology. For wind turbines, a further complication is that the modal frequencies are dependent on the turbine rotation speed. The history and development of a new technique for acquiring the modal parameters using output-only response data, called the Natural Excitation Technique (NExT), will be reviewed, showing historical tests and techniques. The initial attempts at output-only modal testing began in the late 1980's with the development of NExT in the 1990's. NExT was a predecessor to OMA, developed to overcome these challenges of testing immense structures excited with environmental inputs. We will trace the difficulties and successes of wind turbine modal testing from 1982 to the present. Keywords: OMA, Modal Analysis, NExT, Wind Turbines, Wind Excitation

James, George H., III↗

NASA NTRS2019

Investigation of Anti-Phase Asymmetric Quiet Rotor Technology

The future of urban air mobility has a well-known tall pole challenge in the form of community acceptance which largely comes from the noise. This paper presents a proposed anti-phase rotor technology that could reduce noise sources such as blade vortex interaction noise. The anti-phase rotor technology includes a rotor design with various anti-phase alternating trailing edge patterns and a rotor design with an asymmetric blade tip. Four small-scale anti-phase rotors are fabricated by 3D printing for acoustic measurements conducted in a low-speed open-circuit wind tunnel to assess the effectiveness of the proposed anti-phase rotor technology. Preliminary test results appear to be promising and indicate that the anti-phase rotor designs could be a practical means of reducing blade vortex interactions and noise. The four tested anti-phase rotor designs have peak acoustic performance depending on the RPM and thrust which suggests improved performance through design optimization could be achieved for specific mission requirements.

Cramer, Nicholas B.↗

NASA NTRSDate not supplied

Blade Displacement Measurements of a Rotor in Forward Flight in the Langley 14- by 22-Ft Wind Tunnel

Stereo photogrammetry was used to measure the elastic bending and twist of a three-bladed rotor in forward flight in the NASA Langley 14-by 22-Ft Subsonic Wind Tunnel. The rotor was imaged from below by two cameras mounted at windows of a large turntable in the floor of the test section. At each test condition, the turntable and cameras were rotated and the cameras were triggered to allow measurements over a range of blade azimuth angles. Retro-reflective targets were applied along the leading and trailing edges of the lower surface of each blade. Image blur due to blade motion was minimized by illuminating the targets with high-intensity LED flash lamps mounted next to each camera. The cameras were re-calibrated at each angular position of the turntable using the positions in each image of retro-reflective targets on the ceiling of the test section whose spatial coordinates had been very accurately measured. The blade displacement measurements yielded elastic bending and twist along each blade as functions of blade azimuth, thrust coefficient, and advance ratio, all at a constant rotor angle-of-attack. In addition, the measurements produced estimates of the rigid-body blade pitch, flap, and lag angles.

rotor blade displacement↗

NASA NTRSDate not supplied

Blade Displacement Measurements of a Rotor in Forward Flight in the Langley 14-by 22-Foot Wind Tunnel

Stereo photogrammetry was used to measure the elastic bending and twist of a three-bladed rotor in forward flight in the NASA Langley 14-by 22-Ft Subsonic Wind Tunnel. The rotor was imaged from below by two cameras mounted at windows of a large turntable in the floor of the test section. At each test condition, the turntable and cameras were rotated and the cameras were triggered to allow measurements over a range of blade azimuth angles. Retro-reflective targets were applied along the leading and trailing edges of the lower surface of each blade. Image blur due to blade motion was minimized by illuminating the targets with high-intensity LED flash lamps mounted next to each camera. The cameras were re-calibrated at each angular position of the turntable using the positions in each image of retro-reflective targets on the ceiling of the test section whose spatial coordinates had been very accurately measured. The blade displacement measurements yielded elastic bending and twist along each blade as functions of blade azimuth, thrust coefficient, and advance ratio, all at a constant rotor shaft angle. In addition, the measurements produced estimates of the rigid-body blade pitch, flap, and lag angles.

rotor↗

NASA NTRS1972

New technology in turbine aerodynamics

A cursory review is presented of some of the recent work that has been done in turbine aerodynamic research at NASA-Lewis Research Center. Topics discussed include the aerodynamic effect of turbine coolant, high work-factor (ratio of stage work to square of blade speed) turbines, and computer methods for turbine design and performance prediction. An extensive bibliography is included. Experimental cooled-turbine aerodynamics programs using two-dimensional cascades, full annular cascades, and cold rotating turbine stage tests are discussed with some typical results presented. Analytically predicted results for cooled blade performance are compared to experimental results. The problems and some of the current programs associated with the use of very high work factors for fan-drive turbines of high-bypass-ratio engines are discussed. Turbines currently being investigated make use of advanced blading concepts designed to maintain high efficiency under conditions of high aerodynamic loading. Computer programs have been developed for turbine design-point performance, off-design performance, supersonic blade profile design, and the calculation of channel velocities for subsonic and transonic flow fields. The use of these programs for the design and analysis of axial and radial turbines is discussed.

Glassman, A. J.↗

NASA NTRS2006

Space Shuttle Main Engine Low Pressure Oxidizer Turbo-Pump Inducer Dynamic Environment Characterization through Water Model and Hot-Fire Testing

The Low Pressure Oxidizer Turbopump (LPOTP) inducer on the Block II configuration Space Shuttle Main Engine (SSME) experienced blade leading edge ripples during hot firing. This undesirable condition led to a minor redesign of the inducer blades. This resulted in the need to evaluate the performance and the dynamic environment of the redesign, relative to the current configuration, as part of the design acceptance process. Sub-scale water model tests of the two inducer configurations were performed, with emphasis on the dynamic environment due to cavitation induced vibrations. Water model tests were performed over a wide range of inlet flow coefficient and pressure conditions, representative of the scaled operating envelope of the Block II SSME, both in flight and in ground hot-fire tests, including all power levels. The water test hardware, facility set-up, type and placement of instrumentation, the scope of the test program, specific test objectives, data evaluation process and water test results that characterize and compare the two SSME LPOTP inducers are discussed. In addition, dynamic characteristics of the two water models were compared to hot fire data from specially instrumented ground tests. In general, good agreement between the water model and hot fire data was found, which confirms the value of water model testing for dynamic characterization of rocket engine turbomachinery.

Patrick Arellano↗

DOE OSTI2018

Development and Evaluation of a Drone-Deployed Wind Turbine Blade Nondestructive Inspection System

Wind energy is quickly becoming a significant contributor to the United States' overall energy portfolio. Wind turbine blades pose a unique set of inspection challenges that span from very thick and attenuative spar cap structures to porous bond lines, varying core material and a multitude of manufacturing defects of interest. The need for viable, accurate nondestructive inspection (NDI) technology becomes more important as the cost per blade, and lost revenue from downtime, grows. To address this growing need, Sandia and SkySpecs collaborated to evaluate NDI methods that are suitable for integration on an autonomous drone inspection platform. A trade study of these NDI methods was performed, and thermography was selected as the primary technique for further evaluation. Based on the capabilities of SkySpecs' custom inspection drone, a miniature microbolometer IR camera was successfully selected and tested in a benchtop setting. After identifying key operating parameters for inspecting wind blade materials, hardware and software integration of the IR camera was performed, and Sandia and SkySpecs conducted initial field testing. Finally, recommendations for a path forward for drone-deployed thermography inspections were provided.

17 WIND ENERGY↗

NASA NTRS1982

The effect of rotor blade thickness and surface finish on the performance of a small axial flow turbine

An experimental investigation was conducted to determine the effect of blade profile inaccuracies and surface finish on the aerodynamic performance of a 11.13 cm tip diameter turbine. The as-received cast rotor blades had a significantly thicker profile than the design intent and a fairly rough surface finish. Stage test results showed an increase of one point in efficieny by smoothing the surface finish and another three points by thinning the blade profiles to near the design profile. Most of the performance gain between the as-cast thick and the thinned rotor blades both with the same surface finish, was attributed to reduced trailing edge losses of the recontoured blades.

Roelke, R. J.↗

NASA NTRS1980

Performance and noise of a low pressure ratio variable pitch fan designed for general aviation applications

A limited study has been conducted to establish the performance and noise characteristics of a low design tip speed (168 m/s, 550 ft/sec) low pressure ratio (1.04) variable pitch fan which was tested in the Langley 30 X 60 tunnel. This fan was designed for minimum noise when installed in the tail mount location of a twin engine aircraft which normally has both nose and tail mounted propulsors. Measurements showed the fan noise to be very close to predictions made during the design of the fan and extremely low in level (65 dBA at 1000 ft) with no acoustic treatment. This is about 8 dB lower than the unshrouded 2 blade propeller normally used in this installation. On the basis of tests conducted during this program, it appears that this level could be further reduced by 2 dBA if optimized acoustic treatments were installed in the fan duct. Even the best of the shrouded propellers tested previously were 7 dB higher in level than the Q-Fan without acoustic treatment. It was found that the cruise performance of this fan was within 5% of the predicted efficiency of 72%. Evaluation of the performance data indicated that disturbances in the inflow to the fan were the probable cause of the reduced performance.

Metzger, F. B.↗

NASA NTRS1992

Structural testing of the technology integration box beam

A full scale section of a transport aircraft wing box was designed, analyzed, fabricated, and tested. The wing box section, which was called the technology integration box beam, contained blade stiffened covers and T-stiffened channel spars constructed using graphite-epoxy materials. Covers, spars, and the aluminum ribs were assembled using mechanical fasteners. The box beam was statically tested for several loading conditions to verify the stiffness and strength characteristics of the composite wing design. Failure of the box beam occurred at 125 pct. of design limit load during the combined unbending and torsion ultimate design load test. It appears that the failure initiated at a stiffener runout location in the upper cover which resulted in rupture of the upper cover and portions of both spars.

Griffin, C. F.↗

NASA NTRS2012

Tip Vortex and Wake Characteristics of a Counterrotating Open Rotor

One of the primary noise sources for Open Rotor systems is the interaction of the forward rotor tip vortex and blade wake with the aft rotor. NASA has collaborated with General Electric on the testing of a new generation of low noise, counterrotating Open Rotor systems. Three-dimensional particle image velocimetry measurements were acquired in the intra-rotor gap of the Historical Baseline blade set. The velocity measurements are of sufficient resolution to characterize the tip vortex size and trajectory as well as the rotor wake decay and turbulence character. The tip clearance vortex trajectory is compared to results from previously developed models. Forward rotor wake velocity profiles are shown. Results are presented in a form as to assist numerical modeling of Open Rotor system aerodynamics and acoustics.

VanZante, Dale E.↗

NASA NTRS2012

Tip Vortex and Wake Characteristics of a Counterrotating Open Rotor

Van Zante, Dale E.↗

DOE OSTI2025

Overall Cooling Effectiveness of Internally Cooled Additively Manufactured Blades

Power generation gas turbine blades must utilize highly effective cooling schemes to withstand moderate heat loads for long operating times. Prior work indicates that gas turbines in the 5-10 MW range primarily utilize internal cooling to prevent further increase of aerodynamic losses that result from film cooling, but few studies focus solely on internal cooling. In this study, three additively manufactured internal cooling designs were tested in the 50 percent span section of the National Experimental Turbine (NExT) blade: a baseline cooling design with pin-fin arrays and rib turbulators, a double wall design with impingement jets and serpentine channels, and an incremental impingement design. The designs were tested in a high-speed linear cascade at exit Reynolds numbers ranging from 700,000 to 1,400,000 at an exit Mach of 0.8. In addition, freestream turbulence and build angle effects on cooling performance were studied.

gas turbine blades↗

NASA NTRS2010

Propulsion Health Monitoring of a Turbine Engine Disk Using Spin Test Data

This paper considers data collected from an experimental study using high frequency capacitive sensor technology to capture blade tip clearance and tip timing measurements in a rotating turbine engine-like-disk-to predict the disk faults and assess its structural integrity. The experimental results collected at a range of rotational speeds from tests conducted at the NASA Glenn Research Center s Rotordynamics Laboratory are evaluated using multiple data-driven anomaly detection techniques to identify abnormalities in the disk. Further, this study presents a select evaluation of an online health monitoring scheme of a rotating disk using high caliber sensors and test the capability of the in-house spin system.

Abdul-Aziz, Ali↗

NASA NTRS1985

Inviscid analysis of unsteady blade tip flow correlation studies

Two computer programs, VSAERO-TS and VSAERO-H, were used for computing the unsteady subsonic aerodynamic characteristics of arbitrarily shaped wings oscillating in pitch. Program VSAERO-TS is a time-stepping analysis capable of treating large amplitude motions while program VSAERO-H uses harmonic wake and small amplitude assumptions. A comparison between the computed (VSAERO-TS and VSAERO-H) and DFVLR test results for chordwise pressure distributions for rectangular, swept, taper and ogee blade tips is presented in this report. A wide range of angles of attack (mean) from 0 to 12 deg and reduced frequencies of 0.1, 0.2 and 0.3 are covered in this report. Also, the comparison includes several spanwise stations.

Rao, B. M.↗

NASA NTRS1972

Single stage evaluation of highly loaded high Mach number compressor stages. 6: Data and performance of cantilevered stator

A compressor stage with a rotor tip speed of 1600 ft/sec was tested to evaluate its performance with a cantilevered stator and a rotating inner shroud beneath the stator. Both the rotor blades and the stator vanes were composed of multiple circular arc airfoil sections. Comparison of data taken during this test of the cantilevered stator and previous tests with the same compressor and airfoil geometry in a shroud stator configuration showed only slight differences in stage performance with no significant effect on overall efficiency. However, the severity of the stator wake near the rotating hub was decreased at all flows including the near surge condition. Stall and wise open discharge corrected weight flows were the same as for the shrouded stator configuration.

Merrow, A. S.↗

DOE OSTI2014

Erosion-Resistant Nanocoatings for Improved Energy Efficiency in Gas Turbines

The objective of this Stage Gate IV project was to test and substantiate the viability of an erosion-resistant nanocoating for application on compressor airfoils for gas turbines in both industrial power generation and commercial aviation applications. To effectively complete this project, the National Energy Technology Laboratory’s Office of Research & Development teamed with MDS Coating Technologies Inc. (MCT), Delta Air Lines - Technical Operations Division (Delta Tech Ops), and Calpine Corporation. The coating targeted for this application was MCT’s Next Generation Coating, version 4 (NGC-v4 - with the new registered trademark name of BlackGold®). The coating is an erosion and corrosion resistant composite nanostructured coating. This coating is comprised of a proprietary ceramic-metallic nano-composite construction which provides enhanced erosion resistance and also retains the aerodynamic geometry of the airfoils. The objective of the commercial aviation portion of the project was to substantiate the coating properties to allow certification from the FAA to apply an erosion-resistant coating in a commercial aviation engine. The goal of the series of tests was to demonstrate that the durability of the airfoils is not affected negatively with the application of the NGC v4 coating. Tests included erosion, corrosion, vibration and fatigue. The results of the testing demonstrated that the application of the coating did not negatively impact the properties of the blades, especially fatigue performance – which is of importance in acceptance for commercial aviation applications. The objective of the industrial gas turbine element of the project was to evaluate the coating as an enabling technology for inlet fogging during the operation of industrial gas turbines. Fluid erosion laboratory scale tests were conducted to simulate inlet fogging conditions. Results of these tests indicated that the application of the erosion resistant NGC-v4 nanocoating improved the resistance to simulated inlet fogging conditions by a factor of 10 times. These results gave confidence for a field trial at Calpine’s power plant in Corpus Christi, TX, which commenced in April 2012. This test is still on-going as of November 2013, and the nanocoated blades have accumulated over 13,000 operational hours on this specific power plant in approximately 19 months of operation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1981

Full-scale wind-tunnel test of the aeroelastic stability of a bearingless main rotor

The rotor studied in the wind tunnel had previously been flight tested on a BO-105 helicopter. The investigation was conducted to determine the rotor's aeroelastic stability characteristics in hover and at airspeeds up to 143 knots. These characteristics are compared with those obtained from whirl-tower and flight tests and predictions from a digital computer simulation. It was found that the rotor was stable for all conditions tested. At constant tip speed, shaft angle, and airspeed, stability increases with blade collective pitch setting. No significant change in system damping occurred that was attributable to frequency coalescence between the rotor inplane regressing mode and the support modes. Stability levels determined in the wind tunnel were of the same magnitude and yielded the same trends as data obtained from whirl-tower and flight tests.

Warmbrodt, W.↗