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At least 1,549 records · Page 86

Engine cyclic durability by analysis and material testing

The problem of calculating turbine engine component durability is addressed. Nonlinear, finite-element structural analyses, cyclic constitutive behavior models, and an advanced creep-fatigue life prediction method called strainrange partitioning were assessed for their applicability to the solution of durability problems in hot-section components of gas turbine engines. Three different component or subcomponent geometries are examined: a stress concentration in a turbine disk; a louver lip of a half-scale combustor liner; and a squealer tip of a first-stage high-pressure turbine blade. Cyclic structural analyses were performed for all three problems. The computed strain-temperature histories at the critical locations of the combustor linear and turbine blade components were imposed on smooth specimens in uniaxial, strain-controlled, thermomechanical fatigue tests of evaluate the structural and life analysis methods.

Kaufman, A.↗

Engine cyclic durability by analysis and material testing

The problem of calculating turbine engine component durability is addressed. Nonlinear, finite-element structural analyses, cyclic constitutive behavior models, and an advanced creep-fatigue life prediction method called strainrange partitioning were assessed for their applicability to the solution of durability problems in hot-section components of gas turbine engines. Three different component or subcomponent geometries are examined: a stress concentration in a turbine disk; a louver lip of a half-scale combustor linear; and a squealer tip of a first-stage high-pressure turbine blade. Cyclic structural analyses were performed for all three problems. The computed strain-temperature histories at the critical locations of the combustor linear and turbine blade components were imposed on smooth specimens in uniaxial, strain-controlled, thermomechanical fatigue tests of evaluate the structural and life analysis methods.

Kaufman, A.↗

Preliminary Aeroacoustic Measurements from the AART in the NFAC 40-by 80-Foot Wind Tunnel

The primary objective: determine the aerodynamics and acoustics related to an auxiliary propulsor mounted behind an isolated wing in the National Full Scale Aerodynamic Complex 40-by 80-Foot Wind Tunnel. The primary data points match test conditions for in-flow stereo PIV measurements completed in the Ames 7x10 in 2018. The propeller consists of a Sensenich L26H commercial off the shelf blade set and hub, with a 26 inch diameter; propeller performance is measured with an internal balance integrated in the test stand. The wing is a NACA 0015 with a 12 inch chord; 58.5 inches in height for full wing configuration; 40.5 inches in height for the half wing configuration.

Aeroacoustics↗

Structural Evaluation of a Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump Turbine Blade

Thermal and structural finite-element analyses were performed on the first high pressure fuel turbopump turbine blade of the space shuttle main engine (SSME). A two-dimensional (2-D) finite-element model of the blade and firtree disk attachment was analyzed using the general purpose MARC (finite-element) code. The loading history applied is a typical test stand engine cycle mission, which consists of a startup condition with two thermal spikes, a steady state and a shutdown transient. The blade material is a directionally solidified (DS) Mar-M 246 alloy, the blade rotor is forged with waspalloy material. Thermal responses under steady-state and transient conditions were calculated. The stresses and strains under the influence of mechanical and thermal loadings were also determined. The critical regions that exhibited high stresses and severe localized plastic deformation were the blade-rotor gaps.

Abdul-Aziz, Ali↗

Source Diagnostic Fan II (22-inch) Duct Mode Characteristics as Measured by the Rotating Rake Mode Measurement System while Operated in the NASA Glenn 9x15 Low Speed Wind Tunnel

The second entry of the Source Diagnostic Test (SDT2) was a continuation of the first SDT entry with additional parameters tested. The rotor, stators, and general flow path hardware used in SDT2 were the same as those for SDT1. This included a radial baseline set of stator vanes, which had a vane count such that the rotor-stator interaction at the fan blade passing fundamental was cut-off, as is typical for modern turbofans. Two sets of stator vanes were designed and tested with a count generating a cut-on rotor-stator interaction at the fan blade passing fundamental. One of the sets maintained the no aerodynamic sweep as the radial baseline, the other was designed with leading edge sweep with the intent to generate lower noise. The NASA Glenn Research Center’s Rotating Rake Mode Measurement System was utilized to obtain a complete map of the acoustic duct modes present. The system is a radial rake immersed into the duct that continuously rotates about the duct centerline. For each of the three stator vane configurations, data were acquired at several different fan speeds which included nominal, approach, cutback, and takeoff conditions. Analysis of the mode power level results at the fan fundamentals showed the improved designed set resulted in lower rotor-stator interaction mode acoustic levels. Multiple-pure tones generated by the M5 rotor in the inlet were also measured.

Turbofan, Duct Modes↗

Source Diagnostic Fan II (22-inch) Duct Mode Characteristics as Measured by the Rotating Rake Mode Measurement System while Operated in the NASA Glenn 9x15 Low Speed Wind Tunnel

The second entry of the Source Diagnostic Test (SDT2) was a continuation of the first SDT entry with additional parameters tested. The rotor, stators, and general flow path hardware used in SDT2 were the same as those for SDT1. This included a radial baseline set of stator vanes, which had a vane count such that the rotor-stator interaction at the fan blade passing fundamental was cut-off, as is typical for modern turbofans. Two sets of stator vanes were designed and tested with a count generating a cut-on rotor-stator interaction at the fan blade passing fundamental. One of the sets maintained the no aerodynamic sweep as the radial baseline, the other was designed with leading edge sweep with the intent to generate lower noise. The NASA Glenn Research Center’s Rotating Rake Mode Measurement System was utilized to obtain a complete map of the acoustic duct modes present. The system is a radial rake emersed into the duct that continuously rotates about the duct centerline. For each of the three stator vane configurations, data were acquired at several different fan speeds which included nominal, approach, cutback, and takeoff conditions. Analysis of the mode power level results at the fan fundamentals showed the improved designed set resulted in lower rotor-stator interaction mode acoustic levels. Multiple-pure tones generated by the M5 rotor in the inlet were also measured.

Turbofan↗

Single pass rub phenomena - Analysis and experiment

An experimental and analytical investigation is presented of contact phenomena for the case of a fully-dense copper gas path seal segment which is rubbed by a single steel blade tip at room temperature. The experiments were executed on a pendulum-type test device, with forces, rub energy, surface temperature and residual deformation being determined for each single-path rub test. The thermal and mechanical factors influencing single-pass rub surface temperatures were modeled analytically. It is found that large plastic strains occurred on or near the contact surface of the copper rub specimens. A study of the influence of various material properties on surface temperature showed that increased thermal conductivity of the stationary component played a role in lowering contact temperatures. Increased thermal conductivity of the moving blade tip component and increased thermal diffusivity of the stationary material also had a beneficial effect.

Kennedy, F. E.↗

The Development of Modal Testing Technology for Wind Turbines: A Historical Perspective

Wind turbines are very large, flexible structures, with aerodynamic forces on the rotating blades producing periodic forces with frequencies at the harmonics of the rotation frequency. Due to design consideration, these rotational frequencies are comparable to the modal frequencies; thus avoiding resonant conditions is a critical consideration. Consequently, predicting and experimentally validating the modal frequencies of wind turbines has been important to their successful design and operation. Performing modal tests on flexible structures over 120 meters tall is a substantial challenge, which has inspired innovative developments in modal test technology. A further trial to the analyst and experimentalist is that the modal frequencies are dependent on the turbine rotation speed, so testing a parked turbine does not fully validate the analytical predictions. The history and development of this modal testing technology will be reviewed, showing historical tests and techniques, ranging from two-meter to 100-meter turbines for both parked and rotating tests. The NExT (Natural Excitation Technique) was developed in the 1990's, as a predecessor to OMA to overcome these challenges. We will trace the difficulties and successes of wind turbine modal testing over the past twenty-five years from 1982 to the present.

James, George H., III↗

Quiet High Speed Fan (QHSF) Flutter Calculations Using the TURBO Code

A scale model of the NASA/Honeywell Engines Quiet High Speed Fan (QHSF) encountered flutter wind tunnel testing. This report documents aeroelastic calculations done for the QHSF scale model using the blade vibration capability of the TURBO code. Calculations at design speed were used to quantify the effect of numerical parameters on the aerodynamic damping predictions. This numerical study allowed the selection of appropriate values of these parameters, and also allowed an assessment of the variability in the calculated aerodynamic damping. Calculations were also done at 90 percent of design speed. The predicted trends in aerodynamic damping corresponded to those observed during testing.

Bakhle, Milind A.↗

Evaluating the Effectiveness of an Ultrasonic Acoustic Deterrent in Reducing Bat Fatalities at Wind Energy Facilities

This project was designed to use thermal video cameras and fatality monitoring to evaluate the effectiveness of an ultrasonic acoustic deterrent (UAD) on bat activity and mortality, respectively. Our goals were to redesign the UAD device and installation infrastructure, determine the placement on wind turbines to optimize safety, compatibility and functionality, and to compare the mortality among the following conditions: Control (deterrents off and turbines feathered up to the manufacturer’s cut-in speed of 3.5 m/s), Deterrent (deterrents on and turbines feathered up to the manufacturer’s cut-in speed of 3.5 m/s), Curtailment (deterrents off and turbines feathered up to 5/ m/s), and combination (deterrents on and turbines feathered up to 5 m/s). The project was divided into a Feasibility Study and Comparative Study. The objectives for the Feasibility Study were to develop an installation strategy, redesign a previous iteration of a UAD to improve performance and weatherization, and test the effectiveness of the deterrents on bat activity. The Feasibility Study was intended to work out potential issues using a relatively small number of devices prior to manufacturing and installing numerous devices for a larger-scale comparative study. The division of the project into these separate studies was based on previous experience and the challenges of assessing the capabilities of an untested UAD. During the initial development and manufacturing of the UAD, NRG Systems decided to use a piezoelectric transducer rather than an electrostatic transducer, which was used by a previous device (i.e. Deaton UAD). NRG Systems conducted lab testing (i.e., IP67 or Ingress Protection) to ensure no water or dust ingress. In addition, shock/drop trials and variations in temperature exposure were conducted as part of the reliability testing. NRG Systems also developed a communications system to allow for continuous performance monitoring of the UADs. For the Feasibility Study, we installed 6 UADs on each of 2 Gamesa G90 2-MW wind turbines (Turbine 14 and 8) at the South Chestnut Wind Energy Facility, Pennsylvania and monitored activity under control and treatment (i.e. Deterrent) conditions using thermal video monitoring. There are two major sources of variation in bat activity (beyond the anticipated treatment effect): 1) environment around the turbines might inherently favor more activity at one than the other; 2) weather conditions on any given night or within season difference (e.g., migration later during the study period) might favor more activity on some nights than on other nights. Because we could only monitor two turbines on any night, we sought to control the potential influences of these two sources by alternating the turbine on which deterrents were activated each night. If there were no loss of data due to technical failures, this design would result in an equal number of deterrent and control nights at each turbine through the monitoring period, balancing the effects of both sources of variation. We compared the time bats spent and the number of events that occurred in overlapping cameras FOV as an indicator of risk, since 80% of the overlapping FOV of the cameras was in the RSA. Equipment failures, majority due to lightning, resulted in only 17 nights with useable data, with unbalanced treatment assignment within turbines and uneven distribution of treatment assignment throughout the observational period. This resulted in a confounding of treatment assignment and seasonal change. Deterrent treatment was measured at Turbine 14 on only 2 of the first 8 usable nights (spanning the period from 8/18-9/17), whereas 6 times on Turbine 8. From 9/18-927, deterrent was on at Turbine 14 on 6 of the remaining 10 nights, and 4 on Turbine 8. We recorded a total of 1,057 bats and observed a reduction in number of events and duration of events at the UAD-activated turbine when it was Turbine 14. When Turbine 8 had the UAD activated, we observed no difference in number or duration of events. Variation between turbines is not unusual and can cause issues when study designs have no true replication, i.e., multiple turbines per treatment. Within-turbine differences suggested a trend for reduced activity when UADs were activated, particularly for Turbine 14. These results may be caused by the overall higher bat activity at Turbine 8 and confounding of treatment assignment and seasonal trends. We mapped 58 bat events in 3-dimensional space (3D), 30 and 28 events during control and treatment conditions, respectively. We observed bats crossing the rotor plane under both control and treatment conditions and observed a total of 40 confirmed or near-collisions (i.e., target close to blade but no visual confirmation of a strike) out of a total of 1,491 medium and high confidence bat observations (880 control, 611 at treatment). Twice as many collisions/possible collisions were observed during control conditions. Given the challenges with the equipment and potential confounding of the data (i.e., different activity levels at the two wind turbines), we were unable to determine whether this initial turbine placement and orientation was optimal. Given no new information on how best to install the devices, we elected to use the same placement and orientation for the comparative study. For the Comparative Study, the objectives were to investigate the relative mortality rates among 4 treatments. We searched the area within 90 m of each turbine daily to recover the highest number of fresh fatalities possible. We were unable to detect a clear reduction in mortality from deterrents alone for any individual species. Surprisingly, mortality rate of the eastern red bat (Lasiurus borealis) was estimated to be 1.3–4.2 times as much when turbines were operating normally and UADs were on than when UADs were off. Reduction in mortality of all bat species combined due to curtailment of turbines was estimated to be between 0%–38%. This effect was nullified when, in addition to curtailment, UADs were on, with 95% confidence interval ranging from a 45% reduction to a 36% increase in mortality. This was likely due to the large proportion of eastern red bats in the total carcass population. Mortality of all low-frequency echolocating bats combined (i.e. hoary bat [L. cinereus], big brown bat [Eptesicus fuscus], silver-haired bat [Lasionycteris noctivagans]) relative to control was lower when curtailed (95% CI: 0%–74%), but the addition of UADs had no detectable effect (95%CI: 13%–79%). The combined treatment reduced mortality in silver-haired bats relative to control by 11%–99%, compared to curtailment (81% reduction–67% increase) or deterrent (82% reduction–67% increase) alone. Because silver-haired bats comprised a large proportion of low-frequency calling bats found during this study, a similar effect was seen for that group. The higher mortality observed for eastern red bats at UAD compared to control could have been caused by several factors, such as the effective range of the UAD, particularly at higher frequencies, behavior, positioning of the devices on the nacelle, or a combination of these. We used 3D thermal videography to compare control and UAD bat behavior from two turbines using a total of 203 3D bat-tracks across 34 nights. We recorded a similar number of bat-tracks between treatment groups, with 51% and 49% for control and UAD, respectively. Due to potential differences in bat behavior around spinning vs stationary turbine blades, we examined UAD effectiveness separately for non-operating turbines (feathered below cut-in speed of 3.5 m/s) and operating (normal operation above wind speed of 3.5 m/s). We found a higher proportion of bat-tracks at operating turbines (82%) compared to non-operating turbines (18%), although this does not account for overall time turbines were operating versus not. At non-operating turbines the UAD appears to be effective at reducing the amount of time, flight length, and number of passes through the rotor plane, compared to control. In addition, we found bats approached turbines similarly between control and treatment turbines, with 61% of control and 63% of UAD bat-tracks originating leeward of the hub. In contrast, at operating turbines, we saw little change in bat behavior in response to UADs. For example, we found an increase in the average duration of bat-tracks between non-operating and operating turbines for UAD but at control turbines we found average duration decreased once turbines became operational. Both control and UAD had a high proportion of bat-tracks that crossed the rotor plane (i.e., collision risk) originate from the windward side when turbines were operational 65% to 92%, respectively. Given that the UAD devices closest to the blades were orientated parallel to the blades, its possible bats were not exposed to the signal until they were close to the turbine blades, as suggested by the slightly higher mean duration within 5 meters of the blades for UAD turbines. Future research should consider concentrating UAD intensity on the areas of risk (i.e. blades) with enough buffer to allow bats to react to the sound before entering the rotor-swept area (RSA). In addition, investigating the potential of installing UAD units windward of the turbine blades (e.g. a hub-mounted UAD), particularly since even under control conditions, a relatively high proportion (65%) of crosses through the blade plane originated windward. 3D thermal videography provided valuable information on future testing strategies (e.g. device placement, UAD orientation) to improve UAD effectiveness when bats are at risk (i.e., operating wind turbines). Across the entire project we experienced issues with the operation and communication with the UADs. Most of the issues occurred during the Feasibility Study and were resolved prior to the Comparability Study. Additional challenges surfaced during the Comparability Study but were remedied immediately and are thought to have little impact on the results. We had logistical constraints at the project that limited our ability use traditional methods in our camera calibration. Several calibrations showed inaccurate scales, which may have been related to inadequate spatial coverage of “points” in the camera calibration volume. Because we were using actual video recordings of bats at a wind turbine, the behavior of bats could have concentrated “points” in specific areas of the turbine (i.e. leeward of nacelle), and limited “points” in other areas, resulting in camera calibration issues. We have plans to address these inconsistencies and improving the software and related methodologies by early 2020.

17 WIND ENERGY↗

Single-pass rub testing of abradable seal materials

A pendulum-type test device has been built for use in studying rubs between a turbine or compressor blade tip or labyrinth seal knife edge and specimens of abradable gas path seal materials. The device allows measurement of the rub energy dissipated in a single wear event, along with friction and normal forces and wear. Subsequent rubs over the same surface can also be monitored, with microscopic observation of the rub surface being possible after any of the passes. The device was used in tests of several potential abradable materials, ranging from porous to fully dense. It was shown that the rub energy dissipated in initial and subsequent passes is a fundamental parameter in the evaluation of material abradability. Rub energy was found to be influenced by such factors as: density and tensile (or yield) strength of the abradable material, prior densification or work hardening of the rub surface, and the sharpness of the leading edge of the blade tip.

Kennedy, F. E.↗

Studies in a transonic rotor aerodynamics and noise facility

The design, construction and testing of a transonic rotor aerodynamics and noise facility was undertaken, using a rotating arm blade element support technique. This approach provides a research capability intermediate between that of a stationary element in a moving flow and that of a complete rotating blade system, and permits the acoustic properties of blade tip elements to be studied in isolation. This approach is an inexpensive means of obtaining data at high subsonic and transonic tip speeds on the effect of variations in tip geometry. The facility may be suitable for research on broad band noise and discrete noise in addition to high-speed noise. Initial tests were conducted over the Mach number range 0.3 to 0.93 and confirmed the adequacy of the acoustic treatment used in the facility to avoid reflection from the enclosure.

Wright, S. E.↗

Wind tunnel test of a variable-diameter tiltrotor (VDTR) model

This report documents the results from a wind tunnel test of a 1/6th scale Variable Diameter Tiltrotor (VDTR). This test was a joint effort of NASA Ames and Sikorsky Aircraft. The objective was to evaluate the aeroelastic and performance characteristics of the VDTR in conversion, hover, and cruise. The rotor diameter and nacelle angle of the model were remotely changed to represent tiltrotor operating conditions. Data is presented showing the propulsive force required in conversion, blade loads, angle of attack stability and simulated gust response, and hover and cruise performance. This test represents the first wind tunnel test of a variable diameter rotor applied to a tiltrotor concept. The results confirm some of the potential advantages of the VDTR and establish the variable diameter rotor a viable candidate for an advanced tiltrotor. This wind tunnel test successfully demonstrated the feasibility of the Variable Diameter rotor for tilt rotor aircraft. A wide range of test points were taken in hover, conversion, and cruise modes. The concept was shown to have a number of advantages over conventional tiltrotors such as reduced hover downwash with lower disk loading and significantly reduced longitudinal gust response in cruise. In the conversion regime, a high propulsive force was demonstrated for sustained flight with acceptable blade loads. The VDTR demonstrated excellent gust response capabilities. The horizontal gust response correlated well with predictions revealing only half the response to turbulence of the conventional civil tiltrotor.

Matuska, David↗

Assessment of Comprehensive Analysis Calculation of Airloads on Helicopter Rotors

Blade section normal force and pitching moment were investigated for six rotors operating at transition and high speeds: H-34 in flight and wind tunnel, SA 330 (research Puma), SA 349/2, UH-60A full-scale and BO-105 model (HART-I). The measured data from flight and wind tunnel tests were compared with calculations obtained using the comprehensive analysis CAMRAD II. The calculations were made using two free wake models: rolled-up and multiple-trailer with consolidation models. At transition speed, there is fair to good agreement for the blade section normal force between the test data and analysis for the H-34, research Puma, and SA 349/2 with the rolled-up wake. The calculated airloads differ significantly from the measurements for the UH-60A and BO-105. Better correlation is obtained for the UH-60A and BO-105 by using the multiple-trailer with consolidation wake model. In the high speed condition, the analysis shows generally good agreement with the research Puma flight data in both magnitude and phase. However, poor agreement is obtained for the other rotors examined. The analysis shows that the aerodynamic tip design (chord length and quarter chord location) of the Puma has an important influence on the phase correlation.

Yeo, Hyeonsoo↗

A 0.15-scale study of configuration effects on the aerodynamic interaction between main rotor and fuselage

Hover and forward flight tests were conducted to investigate the mutual aerodynamic interaction between the main motor and fuselage of a conventional helicopter configuration. A 0.15-scale Model 222 two-bladed teetering rotor was combined with a 0.15-scale model of the NASA Ames 40x80-foot wind tunnel 1500 horsepower test stand fairing. Configuration effects were studied by modifying the fairing to simulate a typical helicopter forebody. Separation distance between rotor and body were also investigated. Rotor and fuselage force and moment as well as pressure data are presented in graphical and tabular format. Data was taken over a range of thrust coefficients from 0.002 to 0.007. In forward flight speed ratio was varied from 0.1 to 0.3 with shaft angle varying from +4 to -12 deg. The data show that the rotors effect on the fuselage may be considerably more important to total aircraft performance than the effect of the fuselage on the rotor.

Trept, Ted↗

Characterization of a centrifugal pump in He II

As part of an effort to determine the feasibility of helium transfer in space, a centrifugal pump was tested in He II at a variety of flow rates, pump speeds, and fluid temperatures. The pump, which has a straight bladed impeller 6.86 cm in diameter, generated a maximum pressure rise of 15 kPa and a maximum flow rate of 22 g/s for the conditions of the test. Pump performance seems to be independent of fluid temperature and is in good agreement with the values predicted by the manufacturer. Over the range of flow coefficients, the measured maximum efficiency is around 50 percent. Cavitation is observed in the pump and is thought to be highly dependent on the local heating of the helium in the pump. Preliminary measurements of the noise spectra of the pump suggest a possible mechanism to predict the onset of cavitation.

Weisend, J. G., II↗

Hygrothermomechanical evaluation of transverse filament tape epoxy/polyester fiberglass composites

The static and cyclic load behavior of transverse filament tape (TFT) fiberglass/epoxy and TFY fiberglass/polyester composites, intended for use in the design of low-cost wind turbine blades, are presented. The data behavior is also evaluated with respect to predicted properties based on an integrated hygrothermomechanical response theory. Experimental TFT composite data were developed by the testing of laminates made by using composite layups typical of those used for the fabrication of TFT fiberglass wind turbine blades. Static properties include tension, compression, and interlaminar shear strengths at ambient conditions and at high humidity/elevated temperature conditions after a 500 hour exposure. Cyclic fatigue data were obtained using similar environmental conditions and a range of cyclic stresses. The environmental (temperature and moisture) and cyclic load effects on composite strength degradation are subsequently compared with the predictions obtained by using the composite life/durability theory. The results obtained show that the predicted hygrothermomechanical environmental effects on TFT composites are in good agreement with measured data for various properties including fatigue at different cyclic stresses.

Lark, R. L.↗

Explicit Finite Element Modeling of Multilayer Composite Fabric for Gas Turbine Engine Containment Systems, Phase II: Ballistic Impact Testing - Part 2

This report summarizes the ballistic impact testing that was conducted to provide validation data for the development of numerical models of blade-out events in fabric containment systems. The ballistic impact response of two different fiber materials - Kevlar(TradeName) 49 and Zylon(TradeName) AS (as spun) was studied by firing metal projectiles into dry woven fabric specimens using a gas gun. The shape, mass, orientation, and velocity of the projectile were varied and recorded. In most cases, the tests were designed so the projectile would perforate the specimen, allowing measurement of the energy absorbed by the fabric. The results for both Zylon and Kevlar presented here represent a useful set of data for the purposes of establishing and validating numerical models to predict the response of fabrics under conditions that simulate those of a jet engine blade-release situation. In addition, some useful empirical observations were made regarding the effects of projectile orientation and the relative performance of the different fabric materials.

Zylon↗