Typical Sensors Used on Rocket Engine Hot Fire Tests and in-Place Calibration of Facility Flowmeters
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The 60-kilowatt (kW) Zephyr 21/60 wind turbine from Windward Engineering uses a low-cost, full-span independent pitch system that can act as a redundant aerodynamic braking system. This design uses a relatively simple pneumatic rotary vane actuator, allowing each of the turbine's three blades to be pitched independently and any single blade to activate emergency braking for the entire turbine. A previous Competitiveness Improvement Project (CIP) funding award enabled Windward Engineering to design and develop the Zephyr 21/60 wind turbine's aeroelastic model and pitch system. At the end of this current Competitiveness Improvement Project award, a fully validated aeroelastic model will make it possible to certify Windward Engineering's Zephyr 21/60 design and quantify the technology's levelized cost of energy in preparation for certification and entry into the distributed wind market. The Zephyr 21/60 will feature an attractive levelized cost of energy, improved reliability, and a full-span pitch system for safe and redundant protection against rotor overspeed (which occurs when the rotor turns beyond its design limit).
The 'Farnboro' electric indicator was tested as received from the manufacturers, and modifications made to the instrument to improve its operation. The original design of disk valve was altered so as to reduce the mass, travel, and seat area. Changes were made to the recording mechanism, which included a new method of locating the top center position on the record. The effect of friction on the motion of the pointer while taking motoring and power cards was eliminated by providing a means of putting pressure lines on the record. The modified indicator gives a complete record of the average cyclic variation in pressure per crank degree for any set of engine operating conditions which can be held constant for the period of time required to build up the composite card. The value of the record for accurate quantitative measurement is still questioned, although the maximum indicated pressure recorded on the motoring and power cards checks the readings of the balanced diaphragm type of maximum cylinder pressure indicator.
As part of a broad-based NASA program to provide a technology base for future propulsion requirements for powered-lift aircraft, the Quiet, Clean, Short-Haul, Experimental Engine (QCSEE) program was begun by the Lewis Research Center in 1974. The initial buildup of the under-the-wing (UTW) engine was tested by the contractor at his test site. The UTW engine was delivered to Lewis in 1978 for further testing with wing and flap segments simulating an installation on a short-haul transport aircraft. The engine was also tested alone as an aid in identifying the various noise sources and their levels. As part of these tests the aerodynamic profiles at the exhaust nozzle and on the surfaces and in the wake of the wing-flap system were measured. This report documents, in plots and tabular form, the significant results from those tests. The results are presented as tabulations of aerodynamic data for all of the test points and as profiles of pressure, temperature, velocity, and normalized velocity and pressure for selected conditions. One of the main conclusions was that the measured flap surface temperatures were surprisingly low for both approach and takeoff flap settings.
Development and testing of ablative rocket engine with selected 7.62 cm /3.0 in./ diameter throat inserts, and testing of zirconia reinforced with tungsten-rhenium wire for throat insert material
Two air-cooled blades were tested to gas temperatures of 2568 F with coolant temperatures to 764 F. Both average and local blade temperatures were correlated over the range of operating conditions. Calculated and measured blade wall temperatures are compared. Potential operating turbine-inlet temperatures of each blade are discussed.
The results of preliminary acoustic tests of the engine over the wing concept are summarized. The tests were conducted with a small wing section model (32 cm chord) having two flaps set at the landing position, which is 30 and 60 deg respectively. The engine exhaust was simulated by an air jet from a convergent nozzle having a nominal diameter of 5.1 centimeters. Factors investigated for their effect on noise include nozzle location, wing shielding, flap leakage, nozzle shape, exhaust deflectors, and internally generated exhaust noise.
Design, fabrication, and life test of ion engine system using oxide cathode mercury electron bombardment thrustor
A 40 kilowatt Stirling engine, its test support facilities, and the experimental procedures used for these tests are described. Operating experience with the engine is discussed, and some initial test results are presented
An experimental test program was carried out to document all 30-cm electron bombardment Hg ion bombardment thruster functions and characteristics over the thermal environment of several proposed missions. An engineering model thruster was placed in a thermal test facility equipped with -196 C walls and solar simulation. The thruster was cold soaked and exposed to simulated eclipses lasting in duration from 17 to 72 minutes. The thruster was operated at quarter, to full beam power in various thermal configurations which simulated multiple thruster operation, and was also exposed to 1 and 2 suns solar simulation. Thruster control characteristics and constraints; performance, including thrust magnitude and direction; and structural integrity were evaluated over the range of thermal environments tested.
An experimental test program was carried out to document all 30-cm electron bombardment Hg ion bombardment thruster functions and characteristics over the thermal environment of several proposed missions. An engineering model thruster was placed in a thermal test facility equipped with -196 C walls and solar simulation. The thruster was cold soaked and exposed to simulated eclipses lasting in duration from 17 to 72 minutes. The thruster was operated at quarter, to full beam power in various thermal configurations which simulated multiple thruster operation, and was also exposed to 1 and 2 suns solar simulation. Thruster control characteristics and constraints; performance, including thrust magnitude and direction; and structural integrity were evaluated over the range of thermal environments tested.
Wind tunnel tests of supersonic propulsion inlet, engine and exhaust nozzles
The results of the NEXT 2000 h wear test are presented. This test was conducted with a 40 cm engineering model ion engine, designated EM1, at a 3.52 A beam current and 1800 V beam power supply voltage. Performance tests, which were conducted over a throttling range of 1.1 to 6.9 kW throughout the wear test, demonstrated that EM1 satisfied all thruster performance requirements. The ion engine accumulated 2038 h of operation at a thruster input power of 6.9 kW, processing 43 kg of xenon. Overall ion engine performance, which includes thrust, thruster input power, specific impulse, and thrust efficiency, was steady with no indications of performance degradation. The ion engine was also inspected following the test. This paper presents these findings.
The General Electric CF6-50 engine nacelle was originally equipped with both fan nozzle and core nozzle thrust reversers. Many airline operators later deactivated the core reverser. Elimination of the core reverser enabled design changes to be made to help improve performance. A reduction in core nozzle length of approximately two feet was possible. This concept, defined as the Short Core Exhaust Nozzle, was evaluated in engine ground tests, including performance, acoustic, and endurance tests under the NASA/Lewis Engine Component Improvement Program. The test results verified the performance predictions from scale model tests. The Short Core Exhaust Nozzle provides an internal cruise SFC reduction of 0.9% without an increase in engine noise. The nozzle hardware successfully completed 1000 flight cycles of endurance testing with no signs of distress.
The NASA Refan Program included full-scale performance and noise ground tests of both a current production (JT8D-15) and a refanned (JT8D-115) engine. A description of the two ground tests including detailed propulsion, noise, and structural test results is presented. The primary objectives of the total test program were comparison of JT8D-15 and JT8D-115 overall propulsion system performance and noise characteristics and determination of incremental component noise levels. Other objectives of the test program included: (1) determination of acoustic treatment effectiveness; (2) measurement of internal sound pressure levels; (3) measurement of inlet and exhaust hardware performance; (4) determination of center-engine surge margin; and (5) evaluation of certain structural characteristics associated with the 727 refan center-engine inlet duct and JT8D refan engine exhaust system. The JT8D-15 and -115 tests were conducted during September 1974 and January to March 1975, respectively. Analyses of the test data indicated that the JT8D-115, as compared to the JT8D-15, demonstrates a 12.5 percent to 13.2 percent reduction in static specific fuel consumption, and a reduction of 6 to 7 PNdB in a weighted average value of static tone corrected perceived noise level. Separated into noise components, a significant reduction was shown for the inlet fan, aft fan, exhaust duct flow, turbine, and jet noises. However, core noise was increased. Photographs of test stands and test equipment are shown.
The service life of Stirling-engine heater structures of Fe-based high-temperature alloys is predicted using a numerical model based on a linear-damage approach and published test data (engine test data for a Co-based alloy and tensile-test results for both the Co-based and the Fe-based alloys). The operating principle of the automotive Stirling engine is reviewed; the economic and technical factors affecting the choice of heater material are surveyed; the test results are summarized in tables and graphs; the engine environment and automotive duty cycle are characterized; and the modeling procedure is explained. It is found that the statistical scatter of the fatigue properties of the heater components needs to be reduced (by decreasing the porosity of the cast material or employing wrought material in fatigue-prone locations) before the accuracy of life predictions can be improved.