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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Why ceramic engines?

Oil is still a problem for the U.S. and its allies. Transportation uses 61 percent of U.S. oil and its share is increasing, so more efficient technology should be concentrated there. Trucks' share of oil use is increasing because they are already much more efficient than autos. The primary truck opportunities are streamlining, more efficient engines, and shifting freight to railroads. More efficient engines are possible using ceramics to allow elimination of cooling systems and better use of waste exhaust heat. A 60 percent improvement seems possible if ceramics can be made tough enough and durable enough.

Stadler, H. L.↗
NASA NTRS2002

Sol-Gel Derived Hafnia Coatings

Sol-gel derived hafnia coatings are being developed to provide an oxidation protection layer on ultra-high temperature ceramics for potential use in turbine engines (ultra-efficient engine technology being developed by NASA). Coatings using hafnia sol hafnia filler particles will be discussed along with sol synthesis and characterization.

Feldman, Jay D.↗
NASA NTRS1976

Future higher performance O2/H2 engine combustion cycle alternatives

The status of current and projected advanced O2/H2 rocket engine configurations for high-efficiency engine designs is examined. Particular attention is given to engine cycle configurations, operating pressures, and performance characteristics which can be foreseen for the engine configurations past the 1980 era for single-stage-to-orbit boosters and advanced space engines. The discussion covers potential O2/H2 performance gains achievable, engine cycle improvements, and projected O2/H2 engine component efficiency, weight, and other improvements foreseen through future development.

Wagner, W. R.↗
NASA NTRS2003

Probabilistic Aeroelastic Analysis Developed for Turbomachinery Components

Aeroelastic analyses for advanced turbomachines are being developed for use at the NASA Glenn Research Center and industry. However, these analyses at present are used for turbomachinery design with uncertainties accounted for by using safety factors. This approach may lead to overly conservative designs, thereby reducing the potential of designing higher efficiency engines. An integration of the deterministic aeroelastic analysis methods with probabilistic analysis methods offers the potential to design efficient engines with fewer aeroelastic problems and to make a quantum leap toward designing safe reliable engines. In this research, probabilistic analysis is integrated with aeroelastic analysis: (1) to determine the parameters that most affect the aeroelastic characteristics (forced response and stability) of a turbomachine component such as a fan, compressor, or turbine and (2) to give the acceptable standard deviation on the design parameters for an aeroelastically stable system. The approach taken is to combine the aeroelastic analysis of the MISER (MIStuned Engine Response) code with the FPI (fast probability integration) code. The role of MISER is to provide the functional relationships that tie the structural and aerodynamic parameters (the primitive variables) to the forced response amplitudes and stability eigenvalues (the response properties). The role of FPI is to perform probabilistic analyses by utilizing the response properties generated by MISER. The results are a probability density function for the response properties. The probabilistic sensitivities of the response variables to uncertainty in primitive variables are obtained as a byproduct of the FPI technique. The combined analysis of aeroelastic and probabilistic analysis is applied to a 12-bladed cascade vibrating in bending and torsion. Out of the total 11 design parameters, 6 are considered as having probabilistic variation. The six parameters are space-to-chord ratio (SBYC), stagger angle (GAMA), elastic axis (ELAXS), Mach number (MACH), mass ratio (MASSR), and frequency ratio (WHWB). The cascade is considered to be in subsonic flow with Mach 0.7. The results of the probabilistic aeroelastic analysis are the probability density function of predicted aerodynamic damping and frequency for flutter and the response amplitudes for forced response.

Reddy, T. S. R.↗
NASA NTRS2012

Influence of Alternative Engine Concepts on LCTR2 Sizing and Mission Profile

The Large Civil Tiltrotor (LCTR) was developed as part of the NASA Heavy Lift Rotorcraft Systems Investigation in order to establish a consistent basis for evaluating the benefits of advanced technology for large tiltrotors. The concept has since evolved into the second-generation LCTR2, designed to carry 90 passengers for 1,000 nm at 300 knots, with vertical takeoff and landing. This paper examines the impact of advanced propulsion system concepts on LCTR2 sizing. Two concepts were studied: an advanced, single-speed engine with a conventional power turbine layout (Advanced Conventional Engine, or ACE), and a variable-speed power turbine engine (VSPT). The ACE is the lighter engine, but requires a multi-speed (shifting) gearbox, whereas the VSPT uses a lighter, fixed-ratio gearbox. The NASA Design and Analysis of Rotorcraft (NDARC) design code was used to study the trades between rotor and engine efficiency and weight. Rotor performance was determined by Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics (CAMRAD II), and engine performance was estimated with the Numerical Propulsion System Simulation (NPSS). Design trades for the ACE vs. VSPT are presented in terms of vehicle weight empty for variations in mission altitude and range; the effect of different One Engine Inoperative (OEI) criteria are also examined. Because of its strong effect on gearbox weight and on both rotor and engine efficiency, rotor speed was chosen as the reference design variable for comparing design trades. The two propulsion concepts had nearly identical vehicle weights and mission fuel consumption, and their relative advantages varied little with cruise altitude, mission range, or OEI criteria; high cruise altitude and low cruise tip speed were beneficial for both concepts.

Acree, C. W., Jr.↗
NASA NTRS1997

Steady-State Cycle Deck Launcher Developed for Numerical Propulsion System Simulation

One of the objectives of NASA's High Performance Computing and Communications Program's (HPCCP) Numerical Propulsion System Simulation (NPSS) is to reduce the time and cost of generating aerothermal numerical representations of engines, called customer decks. These customer decks, which are delivered to airframe companies by various U.S. engine companies, numerically characterize an engine's performance as defined by the particular U.S. airframe manufacturer. Until recently, all numerical models were provided with a Fortran-compatible interface in compliance with the Society of Automotive Engineers (SAE) document AS681F, and data communication was performed via a standard, labeled common structure in compliance with AS681F. Recently, the SAE committee began to develop a new standard: AS681G. AS681G addresses multiple language requirements for customer decks along with alternative data communication techniques. Along with the SAE committee, the NPSS Steady-State Cycle Deck project team developed a standard Application Program Interface (API) supported by a graphical user interface. This work will result in Aerospace Recommended Practice 4868 (ARP4868). The Steady-State Cycle Deck work was validated against the Energy Efficient Engine customer deck, which is publicly available. The Energy Efficient Engine wrapper was used not only to validate ARP4868 but also to demonstrate how to wrap an existing customer deck. The graphical user interface for the Steady-State Cycle Deck facilitates the use of the new standard and makes it easier to design and analyze a customer deck. This software was developed following I. Jacobson's Object-Oriented Design methodology and is implemented in C++. The AS681G standard will establish a common generic interface for U.S. engine companies and airframe manufacturers. This will lead to more accurate cycle models, quicker model generation, and faster validation leading to specifications. The standard will facilitate cooperative work between industry and NASA. The NPSS Steady-State Cycle Deck team released a batch version of the Steady-State Cycle Deck in March 1996. Version 1.1 was released in June 1996. During fiscal 1997, NPSS accepted enhancements and modifications to the Steady-State Cycle Deck launcher. Consistent with NPSS' commercialization plan, these modifications will be done by a third party that can provide long-term software support.

VanDrei, Donald E.↗
NASA NTRS1997

Flow Analysis of a Gas Turbine Low- Pressure Subsystem

The NASA Lewis Research Center is coordinating a project to numerically simulate aerodynamic flow in the complete low-pressure subsystem (LPS) of a gas turbine engine. The numerical model solves the three-dimensional Navier-Stokes flow equations through all components within the low-pressure subsystem as well as the external flow around the engine nacelle. The Advanced Ducted Propfan Analysis Code (ADPAC), which is being developed jointly by Allison Engine Company and NASA, is the Navier-Stokes flow code being used for LPS simulation. The majority of the LPS project is being done under a NASA Lewis contract with Allison. Other contributors to the project are NYMA and the University of Toledo. For this project, the Energy Efficient Engine designed by GE Aircraft Engines is being modeled. This engine includes a low-pressure system and a high-pressure system. An inlet, a fan, a booster stage, a bypass duct, a lobed mixer, a low-pressure turbine, and a jet nozzle comprise the low-pressure subsystem within this engine. The tightly coupled flow analysis evaluates aerodynamic interactions between all components of the LPS. The high-pressure core engine of this engine is simulated with a one-dimensional thermodynamic cycle code in order to provide boundary conditions to the detailed LPS model. This core engine consists of a high-pressure compressor, a combustor, and a high-pressure turbine. The three-dimensional LPS flow model is coupled to the one-dimensional core engine model to provide a "hybrid" flow model of the complete gas turbine Energy Efficient Engine. The resulting hybrid engine model evaluates the detailed interaction between the LPS components at design and off-design engine operating conditions while considering the lumped-parameter performance of the core engine.

Veres, Joseph P.↗
NASA NTRS2002

Weibull-Based Design Methodology for Rotating Aircraft Engine Structures

The NASA Energy Efficient Engine (E(sup 3)-Engine) is used as the basis of a Weibull-based life and reliability analysis. Each component's life and thus the engine's life is defined by high-cycle fatigue (HCF) or low-cycle fatigue (LCF). Knowing the cumulative life distribution of each of the components making up the engine as represented by a Weibull slope is a prerequisite to predicting the life and reliability of the entire engine. As the engine Weibull slope increases, the predicted lives decrease. The predicted engine lives L(sub 5) (95 % probability of survival) of approximately 17,000 and 32,000 hr do correlate with current engine maintenance practices without and with refurbishment. respectively. The individual high pressure turbine (HPT) blade lives necessary to obtain a blade system life L(sub 0.1) (99.9 % probability of survival) of 9000 hr for Weibull slopes of 3, 6 and 9, are 47,391 and 20,652 and 15,658 hr, respectively. For a design life of the HPT disks having probable points of failure equal to or greater than 36,000 hr at a probability of survival of 99.9 %, the predicted disk system life L(sub 0.1) can vary from 9,408 to 24,911 hr.

Zaretsky, Erwin↗
NASA NTRS2002

New High-Performance SiC Fiber Developed for Ceramic Composites

Sylramic-iBN fiber is a new type of small-diameter (10-mm) SiC fiber that was developed at the NASA Glenn Research Center and was recently given an R&D 100 Award for 2001. It is produced by subjecting commercially available Sylramic (Dow Corning, Midland, MI) SiC fibers, fabrics, or preforms to a specially designed high-temperature treatment in a controlled nitrogen environment for a specific time. It can be used in a variety of applications, but it currently has the greatest advantage as a reinforcement for SiC/SiC ceramic composites that are targeted for long-term structural applications at temperatures higher than the capability of metallic superalloys. The commercial Sylramic SiC fiber, which is the precursor for the Sylramic-iBN fiber, is produced by Dow Corning, Midland, Michigan. It is derived from polymers at low temperatures and then pyrolyzed and sintered at high temperatures using boron-containing sintering aids (ref. 1). The sintering process results in very strong fibers (>3 GPa) that are dense, oxygen-free, and nearly stoichiometric. They also display an optimum grain size that is beneficial for high tensile strength, good creep resistance, and good thermal conductivity (ref. 2). The NASA-developed treatment allows the excess boron in the bulk to diffuse to the fiber surface where it reacts with nitrogen to form an in situ boron nitride (BN) coating on the fiber surface (thus the product name of Sylramic-iBN fiber). The removal of boron from the fiber bulk allows the retention of high tensile strength while significantly improving creep resistance and electrical conductivity, and probably thermal conductivity since the grains are slightly larger and the grain boundaries cleaner (ref. 2). Also, as shown in the graph, these improvements allow the fiber to display the best rupture strength at high temperatures in air for any available SiC fiber. In addition, for CMC applications under oxidizing conditions, the formation of an in situ BN surface layer creates a more environmentally durable fiber surface not only because a more oxidation-resistant BN is formed, but also because this layer provides a physical barrier between contacting fibers with oxidation-prone SiC surface layers (refs. 3 and 4). This year, Glenn demonstrated that the in situ BN treatment can be applied simply to Sylramic fibers located within continuous multifiber tows, within woven fabric pieces, or even assembled into complex product shapes (preforms). SiC/SiC ceramic composite panels have been fabricated from Sylramic-iBN fabric and then tested at Glenn within the Ultra-Efficient Engine Technology Program. The test conditions were selected to simulate those experienced by hot-section components in advanced gas turbine engines. The results from testing at Glenn demonstrate all the benefits expected for the Sylramic-iBN fibers. That is, the composites displayed the best thermostructural performance in comparison to composites reinforced by Sylramic fibers and by all other currently available high-performance SiC fiber types (refs. 3 and 5). For these reasons, the Ultra-Efficient Engine Technology Program has selected the Sylramic-iBN fiber for ongoing efforts aimed at SiC/SiC engine component development.

DiCarlo, James A.↗
NASA NTRS1992

Deformation mechanisms of NiAl cyclicly deformed near the brittle-to-ductile transformation temperature

One of the ongoing challenges of the aerospace industry is to develop more efficient turbine engines. Greater efficiency entails reduced specific strength and larger temperature gradients, the latter of which means higher operating temperatures and increased thermal conductivity. Continued development of nickel-based superalloys has provided steady increases in engine efficiency and the limits of superalloys have probably not been realized. However, other material systems are under intense investigation for possible use in high temperature engines. Ceramic, intermetallic, and various composite systems are being explored in an effort to exploit the much higher melting temperatures of these systems. NiAl is considered a potential alternative to conventional superalloys due to its excellent oxidation resistance, low density, and high melting temperature. The fact that NiAl is the most common coating for current superalloy turbine blades is a tribute to its oxidation resistance. Its density is one-third that of typical superalloys and in most temperature ranges its thermal conductivity is twice that of common superalloys. Despite these many advantages, NiAl requires more investigation before it is ready to be used in engines. Binary NiAl in general has poor high-temperature strength and low-temperature ductility. On-going research in alloy design continues to make improvements in the high-temperature strength of NiAl. The factors controlling low temperature ductility have been identified in the last few years. Small, but reproducible ductility can now be achieved at room temperature through careful control of chemical purity and processing. But the mechanisms controlling the transition from brittle to ductile behavior are not fully understood. Research in the area of fatigue deformation can aid the development of the NiAl system in two ways. Fatigue properties must be documented and optimized before NiAl can be applied to engineering systems. More importantly though, probing the deformation mechanisms operating in fatigue will lead to a better understanding of NiAl's unique characteristics. Low cycle fatigue properties have been reported on binary NiAl in the past year, yet those studies were limited to two temperature ranges: room temperature and near 1000 K. Eventually, fatigue property data will be needed for a wide range of temperatures and compositions. The intermediate temperature range near the brittle-to-ductile transition was chosen for this study to ascertain whether the sharp change occurring in monotonic behavior also occurs under cyclic conditions. An effort was made to characterize the dislocation structures which evolved during fatigue testing and comment on their role in the deformation process.

Antolovich, Stephen D.↗
NASA NTRS2005

Advanced Combustion Modeling for Complex Turbulent Flows

The next generation of aircraft engines will need to pass stricter efficiency and emission tests. NASA's Ultra-Efficient Engine Technology (UEET) program has set an ambitious goal of 70% reduction of NO(x) emissions and a 15% increase in fuel efficiency of aircraft engines. We will demonstrate the state-of-the-art combustion tools developed a t Stanford's Center for Turbulence Research (CTR) as part of this program. In the last decade, CTR has spear-headed a multi-physics-based combustion modeling program. Key technologies have been transferred to the aerospace industry and are currently being used for engine simulations. In this demo, we will showcase the next-generation combustion modeling tools that integrate a very high level of detailed physics into advanced flow simulation codes. Combustor flows involve multi-phase physics with liquid fuel jet breakup, evaporation, and eventual combustion. Individual components of the simulation are verified against complex test cases and show excellent agreement with experimental data.

Ham, Frank Stanford↗
NASA NTRS1978

Propulsion

NASA aims at developing propulsion technology to reduce the fuel consumption of present engines by 5%, that of new engines of the late 1980s by at least 12%, and that of an advanced early 1990s turboprop by an additional 15%. This paper reviews three separate NASA programs which take up these aims. They are, respectively, Engine Component Improvement, Energy Efficient Engine, and Advanced Turboprops.

Nored, D. L.↗
NASA NTRS1991

Thick thermal barrier coatings for diesel components

An engineered thick thermal barrier coating consisting of multiple layers of zirconia and CoCrAlY with a zirconia top layer and having a system thermal conductance less than 410 w/m(exp 2)K exceeded the 100 hour engine durability goals set forth in this program. The thermal barrier coatings were intact at the test conclusion. Back to back single cylinder research engine tests were conducted with watercooled, metal hardware and oil-cooled, thermal barrier coating insulated hardware to determine apparent heat release and fuel economy. Apparent heat release data revealed that the insulated engine had a shorter ignition delay and a longer combustion duration than the metal engine. The insulated engine fuel economy was approximately two percent worse on average for this series of tests. There was no attempt to optimize engine efficiency of the insulated engine by modifying the engine timing, coating, or other techniques.

Yonushonis, T. M.↗
NASA NTRS2005

Very Tough, Erosion-Resistant Turbine Airfoil Thermal Barrier Coatings Developed

Ceramic thermal barrier coatings (TBCs) are receiving increased attention for advanced gas turbine engine applications. These coatings are considered to be technologically important because of their ability to further increase engine operating temperatures and reduce cooling requirements, thus achieving higher engine efficiency, lower emissions, and increased performance goals. To take full advantage of the capabilities of these coatings, researchers need to use an aggressive design approach whenever possible--one that allows greater temperature reductions through the coating systems and less cooling air to the components. Advanced TBCs that have significantly lower thermal conductivity and better thermal stability than current coatings have been developed for future ultra-efficient, low-emission engine systems. Multicomponent-doped, defect-clustered TBCs have been shown to offer the low conductivity and high stability required for future high-temperature engine applications.

Zhu, Dong-Ming↗
NASA NTRS2010

Efficient Parallel Engineering Computing on Linux Workstations

A C software module has been developed that creates lightweight processes (LWPs) dynamically to achieve parallel computing performance in a variety of engineering simulation and analysis applications to support NASA and DoD project tasks. The required interface between the module and the application it supports is simple, minimal and almost completely transparent to the user applications, and it can achieve nearly ideal computing speed-up on multi-CPU engineering workstations of all operating system platforms. The module can be integrated into an existing application (C, C++, Fortran and others) either as part of a compiled module or as a dynamically linked library (DLL).

Lou, John Z.↗
NASA NTRS2019

Using Machine Learning to Predict Core Sizes of High-Efficiency Turbofan Engines

With the rise in big data and analytics, machine learning is transforming many industries. It is being increasingly employed to solve a wide range of complex problems, producing autonomous systems that support human decision-making. For the aircraft engine industry, machine learning of historical and existing engine data could provide insights that help drive for better engine design. This work explored the application of machine learning to engine preliminary design. Engine core-size prediction was chosen for the first study because of its relative simplicity in terms of number of input variables required (only three). Specifically, machine-learning predictive tools were developed for turbofan engine core-size prediction, using publicly available data of two hundred manufactured engines and engines that were studied previously in NASA aeronautics projects. The prediction results of these models show that, by bringing together big data, robust machine-learning algorithms and automation, a machine learning-based predictive model can be an effective tool for turbofan engine core-size prediction. The promising results of this first study paves the way for further exploration of the use of machine learning for aircraft engine preliminary design.

Tong, Michael T.↗
NASA NTRS2019

Using Machine Learning to Predict Core Sizes of High-Efficiency Turbofan Engines

With the rise in big data and analytics, machine learning is transforming many industries. It is being increasingly employed to solve a wide range of complex problems, producing autonomous systems that support human decision-making. For the aircraft engine industry, machine learning of historical and existing engine data could provide insights that help drive for better engine design. This work explored the application of machine learning to engine preliminary design. Engine core-size prediction was chosen for the first study because of its relative simplicity in terms of number of input variables required (only three). Specifically, machine-learning predictive tools were developed for turbofan engine core-size prediction, using publicly available data of two hundred manufactured engines and engines that were studied previously in NASA aeronautics projects. The prediction results of these models show that, by bringing together big data, robust machine-learning algorithms and data science, a machine learning-based predictive model can be an effective tool for turbofan engine core-size prediction. The promising results of this first study paves the way for further exploration of the use of machine learning for aircraft engine preliminary design.

Core Size↗