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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Materials, Manufacturing, and Test Development of a Composite Fan Blade Leading Edge Subcomponent for Improved Impact Resistance

Application of polymer matrix composite materials for jet engine fan blades is becoming attractive as an alternative to metallic blades; particularly for large engines where significant weight savings are recognized on moving to a composite structure. However, the weight benefit of the composite is offset by a reduction of aerodynamic efficiency resulting from a necessary increase in blade thickness; relative to the titanium blades. Blade dimensions are largely driven by resistance to damage on bird strike. Further development of the composite material is necessary to allow composite blade designs to approximate the dimensions of a metallic fan blade. The reduction in thickness over the state of the art composite blades is expected to translate into structural weight reduction, improved aerodynamic efficiency, and therefore reduced fuel consumption. This paper presents test article design, subcomponent blade leading edge fabrication, test method development, and initial results from ballistic impact of a gelatin projectile on the leading edge of composite fan blades. The simplified test article geometry was developed to realistically simulate a blade leading edge while decreasing fabrication complexity. Impact data is presented on baseline composite blades and toughened blades; where a considerable improvement to impact resistance was recorded.

Materials↗
NASA NTRS2007

Improved C/SiC Ceramic Composites Made Using PIP

Improved carbon-fiber-reinforced SiC ceramic-matrix composite (C/SiC CMC) materials, suitable for fabrication of thick-section structural components, are producible by use of a combination of raw materials and processing conditions different from such combinations used in the prior art. In comparison with prior C/SiC CMC materials, these materials have more nearly uniform density, less porosity, and greater strength. The majority of raw-material/processing-condition combinations used in the prior art involve the use of chemical vapor infiltration (CVI) for densifying the matrix. In contrast, in synthesizing a material of the present type, one uses a combination of infiltration with, and pyrolysis of, a preceramic polymer [polymer infiltration followed by pyrolysis (PIP)]. PIP processing is performed in repeated, tailored cycles of infiltration followed by pyrolysis. Densification by PIP processing takes less time and costs less than does densification by CVI. When one of these improved materials was tested by exposure to a high-temperature, inert-gas environment that caused prior C/SiC CMCs to lose strength, this material did not lose strength. (Information on the temperature and exposure time was not available at the time of writing this article.) A material of the present improved type consists, more specifically, of (1) carbon fibers coated with an engineered fiber/matrix interface material and (2) a ceramic matrix, containing SiC, derived from a pre-ceramic polymer with ceramic powder additions. The enhancements of properties of these materials relative to those of prior C/SiC CMC materials are attributable largely to engineering of the fiber/ matrix interfacial material and the densification process. The synthesis of a material of this type includes processing at an elevated temperature to a low level of open porosity. The approach followed in this processing allows one to fabricate not only simple plates but also more complexly shaped parts. The carbon fiber reinforcement in a material of this type can be in any of several alternative forms, including tow, fabric, or complex preforms containing fibers oriented in multiple directions.

Easler, Timothy↗
NASA NTRS1984

HYTESS: A hypothetical turbofan engine simplified simulation

A users manual for a hypothetical turbofan engine simplified simulation is presented. This digital simulation exists as FORTRAN source code. The program is self-contained and was developed to offer those interested in engine dynamics and controls research an efficient, realistic, and easily used engine simulation. The engine is modeled using a state space formulation. Matrix elements within the linear state space structure are nonlinear functions of various engine variables.

Merrill, W. C.↗
NASA NTRS1983

Measurements of heat transfer distribution over the surfaces of highly loaded turbine nozzle guide vanes

The results of an experimental study of aerodynamic (surface velocity) and heat transfer distributions over the surfaces of two different, highly loaded, low-solidity contemporary turbine vane designs are presented. The aerodynamic configurations of the two vanes were carefully selected to emphasize fundamental differences in the character of the solution surface pressure distributions and the consequent effect on surface heat transfer distributions. The experimental measurements were made in moderate-temperature, three-vane cascades under steady-state conditions. The principal independent parameters (Mach number, Reynolds number, turbulence intensity, and wall-to-gas temperature ratio) were varied over ranges consistent with actual engine operation, and the heat matrix was structured to provide an assessment of the independent influence of each parameter. These measurements are intended to serve as verification data for a parallel analytical code development effort. The results of this parallel effort are briefly reviewed, and the principal conclusions to date are summarized.

Nealy, D. A.↗
NASA NTRS1988

The effects of leading edge and downstream film cooling on turbine vane heat transfer

The progress under contract NAS3-24619 toward the goal of establishing a relevant data base for use in improving the predictive design capabilities for external heat transfer to turbine vanes, including the effect of downstream film cooling with and without leading edge showerhead film cooling. Experimental measurements were made in a two-dimensional cascade previously used to obtain vane surface heat transfer distributions on nonfilm cooled airfoils under contract NAS3-22761 and leading edge showerhead film cooled airfoils under contract NAS3-23695. The principal independent parameters (Mach number, Reynolds number, turbulence, wall-to-gas temperature ratio, coolant-to-gas temperature ratio, and coolant-to-gas pressure ratio) were maintained over ranges consistent with actual engine conditions and the test matrix was structured to provide an assessment of the independent influence of parameters of interest, namely, exit Mach number, exit Reynolds number, coolant-to-gas temperature ratio, and coolant-to-gas pressure ratio. Data provide a data base for downstream film cooled turbine vanes and extends the data bases generated in the two previous studies. The vane external heat transfer obtained indicate that considerable cooling benefits can be achieved by utilizing downstream film cooling. The data obtained and presented illustrate the interaction of the variables and should provide the airfoil designer and computational analyst the information required to improve heat transfer design capabilities for film cooled turbine airfoils.

Hylton, L. D.↗
NASA NTRS1989

Composite sizing and ply orientation for stiffness requirements using a large finite element structural model

A NASTRAN bulk dataset preprocessor was developed to facilitate the integration of filamentary composite laminate properties into composite structural resizing for stiffness requirements. The NASCOMP system generates delta stiffness and delta mass matrices for input to the flutter derivative program. The flutter baseline analysis, derivative calculations, and stiffness and mass matrix updates are controlled by engineer defined processes under an operating system called CBUS. A multi-layered design variable grid system permits high fidelity resizing without excessive computer cost. The NASCOMP system uses ply layup drawings for basic input. The aeroelastic resizing for stiffness capability was used during an actual design exercise.

Radovcich, N. A.↗
NASA NTRS1997

Validation of Framework Code Approach to a Life Prediction System for Fiber Reinforced Composites

The grant was conducted by the MMC Life Prediction Cooperative, an industry/government collaborative team, Ohio Aerospace Institute (OAI) acted as the prime contractor on behalf of the Cooperative for this grant effort. See Figure I for the organization and responsibilities of team members. The technical effort was conducted during the period August 7, 1995 to June 30, 1996 in cooperation with Erwin Zaretsky, the LERC Program Monitor. Phil Gravett of Pratt & Whitney was the principal technical investigator. Table I documents all meeting-related coordination memos during this period. The effort under this grant was closely coordinated with an existing USAF sponsored program focused on putting into practice a life prediction system for turbine engine components made of metal matrix composites (MMC). The overall architecture of the NMC life prediction system was defined in the USAF sponsored program (prior to this grant). The efforts of this grant were focussed on implementing and tailoring of the life prediction system, the framework code within it and the damage modules within it to meet the specific requirements of the Cooperative. T'he tailoring of the life prediction system provides the basis for pervasive and continued use of this capability by the industry/government cooperative. The outputs of this grant are: 1. Definition of the framework code to analysis modules interfaces, 2. Definition of the interface between the materials database and the finite element model, and 3. Definition of the integration of the framework code into an FEM design tool.

Gravett, Phillip↗
NASA NTRS1999

Approaches to New Endcaps for Improved Oxidation Resistance

Norbornenyl-end capped PMR polyimide resins are widely used as polymer matrix composite materials for aircraft engine applications, since they combine ease of processing with good oxidative stability up to 300 C. PMR resins are prepared by a two-step approach involving the initial formation of oligomeric pre-polymers capped at both ends by a latent reactive end cap. The end cap undergoes cross-linking during higher temperature processing, producing the desired low density, high specific strength materials, for PMR- 15. The end cap facilitates processing by controlling the molecular weight of the oligomer and allowing flow before it cross-links. However, after cross-linking, this very end cap accounts for much of the weight loss in the polymer on aging in air at elevated temperatures. Understanding this degradation provides clues for designing new end caps to slow down degradation, and prolong the lifetime of the material.

Meador, Mary Ann B.↗
NASA NTRS2003

Coupled Multi-Disciplinary Optimization for Structural Reliability and Affordability

A computational simulation method is presented for Non-Deterministic Multidisciplinary Optimization of engine composite materials and structures. A hypothetical engine duct made with ceramic matrix composites (CMC) is evaluated probabilistically in the presence of combined thermo-mechanical loading. The structure is tailored by quantifying the uncertainties in all relevant design variables such as fabrication, material, and loading parameters. The probabilistic sensitivities are used to select critical design variables for optimization. In this paper, two approaches for non-deterministic optimization are presented. The non-deterministic minimization of combined failure stress criterion is carried out by: (1) performing probabilistic evaluation first and then optimization and (2) performing optimization first and then probabilistic evaluation. The first approach shows that the optimization feasible region can be bounded by a set of prescribed probability limits and that the optimization follows the cumulative distribution function between those limits. The second approach shows that the optimization feasible region is bounded by 0.50 and 0.999 probabilities.

Abumeri, Galib H.↗
NASA NTRS2002

NMR Guided Design of Endcaps With Improved Oxidation Resistance

A polyimide is a polymer composed of alternating units of diamine and dianhydride, linked to each other via an imide bond. PMR polyimides, commonly used in the aerospace industry, are generally capped at each end by a norbornene endcap which serves a double function: (1) It limits the number of repeating units and, hence, the average molecular weight of the various polymer chains (oligomers), thereby improving processibility; (2) Upon further treatment (curing), the endcap crosslinks the various oligomer strands into a tough heat-resistant piece. Norbornenyl-end capped PMR polyimide resins' are widely used as polymer matrix composite materials for aircraft engine applications,2 since they combine ease of processing with good oxidative stability up to 300 C. PMR resins are prepared by a twestep approach involving the initial formation of oligomeric pre-polymers capped at both ends by a latent reactive end cap. The end cap undergoes cross-linking during higher temperature processing, producing the desired low density, high specific strength materials, as shown for PMR-15.

Meador, Mary Ann B.↗
NASA NTRS2011

Mechanical Properties and Durability of Advanced Environmental Barrier Coatings in Calcium-Magnesium-Alumino-Silicate Environments

Environmental barrier coatings are being developed and tested for use with SiC/SiC ceramic matrix composite (CMC) gas turbine engine components. Several oxide and silicate based compositons are being studied for use as top-coat and intermediate layers in a three or more layer environmental barrier coating system. Specifically, the room temperature Vickers-indentation-fracture-toughness testing and high-temperature stability reaction studies with Calcium Magnesium Alumino-Silicate (CMAS or "sand") are being conducted using advanced testing techniques such as high pressure burner rig tests as well as high heat flux laser tests.

Miladinovich, Daniel S.↗
NASA NTRS2011

Improvements to a Response Surface Thermal Model for Orion

A study was performed to determine if a Design of Experiments (DOE)/Response Surface Methodology could be applied to on-orbit thermal analysis and produce a set of Response Surface Equations (RSE) that predict Orion vehicle temperatures within 10 F. The study used the Orion Outer Mold Line model. Five separate factors were identified for study: yaw, pitch, roll, beta angle, and the environmental parameters. Twenty-three external Orion components were selected and their minimum and maximum temperatures captured over a period of two orbits. Thus, there are 46 responses. A DOE case matrix of 145 runs was developed. The data from these cases were analyzed to produce a fifth order RSE for each of the temperature responses. For the 145 cases in the DOE matrix, the agreement between the engineering data and the RSE predictions was encouraging with 40 of the 46 RSEs predicting temperatures within the goal band. However, the verification cases showed most responses did not meet the 10 F goal. After reframing the focus of the study to better align the RSE development with the purposes of the model, a set of RSEs for both the minimum and maximum radiator temperatures was produced which predicted the engineering model output within +/-4 F. Therefore, with the correct application of the DOE/RSE methodology, RSEs can be developed that provide analysts a fast and easy way to screen large numbers of environments and assess proposed changes to the RSE factors.

Miller, Stephen W.↗
NASA NTRSDate not supplied

Exploring Airfoil Table Generation using XFOIL and OVERFLOW

The rotorcraft design process is a continuously evolving field of research that incorporates a number of software programs. An accurate airfoil table is critical in the design and testing process for rotorcraft. With multiple flow solvers available and flow conditions of multirotor UAM vehicles potentially covering a wide range of Reynolds and Mach numbers, a documented approach for developing airfoil tables is needed. Using benchmark data from legacy airfoil tables and wind tunnel tests for comparison, simulations for a comprehensive test matrix could guide rotorcraft design engineers in generating their own airfoil tables using the XFOIL and OVERFLOW solvers. The motivation for this study is to investigate flow solver features to develop a best practices document for airfoil table generation. The study uses the OVERFLOW and XFOIL flow solvers, coupled with the airfoil table generator AFTGen, to analyze three airfoils for a specific Reynolds numbers flow regime and provide details on how well each flow solver performs within a specific angle of attack range, Mach number range, Reynolds number range, and in different flow conditions, such as turbulent and transitional flow. OVERFLOW analyses in AFTGen for fully turbulent and transition flow are compared with XFOIL results and experimental test data for the section lift, section drag, and pressure coefficients. XFOIL ultimately yields results that are accurate within the linear angle of attack range and below a Mach number of 0.4 but tends to overpredict lift and underpredict drag unless the flow is in the compressible regime. XFOIL cannot accurately model stall and post-stall conditions due to the nature of the solver. This is evident in nearly every case run with XFOIL, where the linear range is usually predicted acceptably and the lift coefficient is overpredicted as the stall angle of attack is approached (with the exception being the generally poor correlation with most of the SSC-A09 cases). OVERFLOW is limited at low Mach numbers, and appears to perform best at Mach numbers of 0.4 and above. The exploration of airfoil table generation using XFOIL and OVERFLOW yielded moderately successful results for the NACA 0012 airfoil, reasonably good results for the RC(4)-10 airfoil, and less accurate results for the SSC-A09 airfoil.

Airfoil Table Generation↗
NASA NTRS2022

Natural Gas/Oxygen Burner Rig at The NASA Glenn Materials Research Laboratory

This technical memorandum describes the development of a new natural gas/oxygen (NG/O2) fueled burner rig to be used for high-temperature environmental durability studies of advanced materials and components at atmospheric pressure. The burner simulates the high-temperature, high-heat flux, and high-velocity thermal environments encountered in aerospace applications. It will be used to study environmental effects such as water vapor interactions relevant to advanced gas turbine engine materials such as ceramic matrix composites with protective environmental barrier coatings. The highest sample temperature achieved to date in a study of the oxidation and recession of monolithic silicon carbide is 3000 °F.

Burner Rig↗
NASA NTRSDate not supplied

Development of Luminescence Lifetime-Based Surface Temperature Mapping for Environmental Barrier Coatings

Luminescence lifetime-based temperature mapping for thermal barrier coatings (TBCs) has been previously demonstrated up to temperatures approaching 1200 °C. Advantages of this method include insensitivities to reflected radiation and emissivity uncertainties. Because of a push towards greater efficiency turbine engine operation using higher turbine inlet temperatures, there is an ongoing movement from TBC-coated superalloy turbine engine components to SiC/SiC ceramic matrix composite components protected by environmental barrier coatings (EBCs). The useful application of luminescence lifetime-based temperature mapping to EBCs requires a significant increase in high temperature capability from below 1200 °C up into the 1300 to 1500 °C temperature range where the much higher background thermal radiation is a challenging issue. In addition, the luminescing sensing layer must exhibit thermochemical compatibility with the EBC. To meet these requirements, Er-doped Y 2 SiO 5 was selected as the luminescing sensor layer material both for its enhanced temperature sensitivity above 1300 °C and its compatibility with rare-earth disilicate EBC topcoats. Both localized spot temperature measurements as well as luminescence lifetime imaging-based temperature mapping were demonstrated up to 1560 °C for Er-doped Y 2 SiO 5 disks. In addition, temperature mapping capability was demonstrated from a 15 µm thick Er-doped Y 2 SiO 5 layer at the surface of a Sc 2 Si 2 O 7 based EBC topcoat. Both localized spot and temperature mapping by luminescence lifetime imaging were demonstrated up to 1380 °C (upper temperature limit of this slurry-based layered EBC) with excellent suppression of background thermal radiation and no degradation of the Er-doped Y 2 SiO 5 temperature sensing surface layer. The source of the novel enhanced temperature sensitivity above 1300 °C will be discussed as well as a path towards compatibility between sensing layer and EBC topcoat to higher temperatures.

temperature measurement↗
NASA NTRSDate not supplied

Foreign Object Damage in Yb 2 Si 2 O 7 Environmental Barrier Coatings

Environmental Barrier Coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s second generation Ytterbium Disilicate EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline Ytterbium Disilicate EBC to the that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

environmental barrier coatings (EBCs)↗
NASA NTRS1993

NDE of titanium alloy MMC rings for gas turbine engines

Progress in the processing and fabrication of metal matrix composites (MMC's) requires appropriate mechanical and nondestructive testing methods. These methods are needed to characterize properties, assess integrity, and predict the life of engine components such as compressor rotors, blades, and vanes. Capabilities and limitations of several state-of-the-art nondestructive evaluation (NDE) technologies are investigated for characterizing titanium MMC rings for gas turbine engines. The use of NDE technologies such as x-ray computed tomography, radiography, and ultrasonics in identifying fabrication-related problems that caused defects in components is examined. Acousto-ultrasonics was explored to assess degradation of material mechanical properties by using stress wave factor and ultrasonic velocity measurements before and after the burst testing of the rings.

Baaklini, George Y.↗
NASA NTRSDate not supplied

Composite Materials Handbook 17 (CMH-17) Volume 5—Ceramic Matrix Composites

The intent of the Composite Materials Handbook‐17 (CMH‐17) Vol 5A—Ceramic Matrix Composites is that it will provide the information and guidance necessary to design, fabricate, and implement ceramic matrix composite components for commercial aircraft engines. The CMH-17 sponsor is the FAA (Federal Aviation Administration). This presentation describes the updating of the handbook, and covers the objectives and activities of the Working Groups that are preparing new content and revising existing text. The 5 Working Groups are: 1) Data Review, 2) Testing, 3) Materials & Processes, 4) Design and Analysis, and 5) Engine Applications. Goal: release Vol 5B in 2023.

Environmental barrier coating (EBC), Ceramic Matri↗