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At least 433 records · Page 24

Actively controlled shaft seals for aerospace applications

An electronically controlled mechanical seal for use as the purge gas seal in a liquid oxygen turbo pump has been fabricated and tested under transient operating conditions. The thickness of the lubricating film is controlled by adjusting the coning of the carbon face. This is accomplished by applying a voltage to a piezoelectric actuator to which the carbon face is bonded. The seal has been operated with a closed-loop control system that utilizes either the leakage rate or the seal face temperature as the feedback. Both speed and pressure transients have been imposed on the seal. The transient tests have demonstrated that the seal is capable of maintaining low leakage rates while limiting the face temperatures.

Salant, Richard F.↗

Brush seals for cryogenic applications

Brush seals are compliant, contacting seals and have significantly lower leakage than labyrinth seals in gas turbine applications. Their characteristics of long life and low leakage make them candidates for use in rocket engine turbopumps. Two-inch diameter brush seals with a nominal 0.005 inch radial interference were tested in liquid nitrogen at shaft speeds up to 35,000 rpm and pressure drops up to 175 psid per seal. A labyrinth seal was also tested to provide a baseline. Performance, staging effects, and wear results are presented.

Proctor, Margaret P.↗

Air Force seal activities

Seal technology development is an important part of the Air Force's participation in the Integrated High Performance Turbine Engine Technology (IHPTET) initiative, the joint DOD, NASA, ARPA, and industry endeavor to double turbine engine capabilities by the turn of the century. Significant performance and efficiency improvements can be obtained through reducing internal flow system leakage, but seal environment requirements continue to become more extreme as the engine thermodynamic cycles advance towards these IHPTET goals. Brush seal technology continues to be pursued by the Air Force to reduce leakage at the required conditions. Likewise, challenges in engine mainshaft air/oil seals are also being addressed. Counter-rotating intershaft applications within the IHPTET initiative involve very high rubbing velocities. This viewgraph presentation briefly describes past and current seal research and development programs and gives a summary of seal applications in demonstrator and developmental engine testing.

Mayhew, Ellen R.↗

Numerical Simulation of Flow in a Whirling Annular Seal and Comparison with Experiments

The turbulent flow field in a simulated annular seal with a large clearance/radius ratio (0.015) and a whirling rotor was simulated using an advanced 3D CFD code SCISEAL. A circular whirl orbit with synchronous whirl was imposed on the rotor center. The flow field was rendered quasi-steady by making a transformation to a totaling frame. Standard k-epsilon model with wall functions was used to treat the turbulence. Experimentally measured values of flow parameters were used to specify the seal inlet and exit boundary conditions. The computed flow-field in terms of the velocity and pressure is compared with the experimental measurements inside the seal. The agreement between the numerical results and experimental data with correction is fair to good. The capability of current advanced CFD methodology to analyze this complex flow field is demonstrated. The methodology can also be extended to other whirl frequencies. Half- (or sub-) synchronous (fluid film unstable motion) and synchronous (rotor centrifugal force unbalance) whirls are the most unstable whirl modes in turbomachinery seals, and the flow code capability of simulating the flows in steady as well as whirling seals will prove to be extremely useful in the design, analyses, and performance predictions of annular as well as other types of seals.

Athavale, M. M.↗

Electronically controlled mechanical seal for aerospace applications--Part 2: Transient tests

An electronically controlled mechanical seal for use as the purge gas seal in a liquid oxygen turbopump has been fabricated and tested under transient operating conditions. The thickness of the lubricating film is controlled by adjusting the coning of the carbon face. This is accomplished by applying a voltage to a piezoelectric actuator to which the carbon face is bonded. The seal has been operated with a closed-loop control system that utilizes either the leakage rate or seal face temperature as the feedback. Both speed and pressure transients have been imposed on the seal. The transient tests have demonstrated that the seal is capable of maintaing low leakage rates while limiting face temperatures.

Wolff, Paul J.↗

Analysis of Two-Phase Flow in Damper Seals for Cryogenic Turbopumps

Cryogenic damper seals operating close to the liquid-vapor region (near the critical point or slightly su-cooled) are likely to present two-phase flow conditions. Under single phase flow conditions the mechanical energy conveyed to the fluid increases its temperature and causes a phase change when the fluid temperature reaches the saturation value. A bulk-flow analysis for the prediction of the dynamic force response of damper seals operating under two-phase conditions is presented as: all-liquid, liquid-vapor, and all-vapor, i.e. a 'continuous vaporization' model. The two phase region is considered as a homogeneous saturated mixture in thermodynamic equilibrium. Th flow in each region is described by continuity, momentum and energy transport equations. The interdependency of fluid temperatures and pressure in the two-phase region (saturated mixture) does not allow the use of an energy equation in terms of fluid temperature. Instead, the energy transport is expressed in terms of fluid enthalpy. Temperature in the single phase regions, or mixture composition in the two phase region are determined based on the fluid enthalpy. The flow is also regarded as adiabatic since the large axial velocities typical of the seal application determine small levels of heat conduction to the walls as compared to the heat carried by fluid advection. Static and dynamic force characteristics for the seal are obtained from a perturbation analysis of the governing equations. The solution expressed in terms of zeroth and first order fields provide the static (leakage, torque, velocity, pressure, temperature, and mixture composition fields) and dynamic (rotordynamic force coefficients) seal parameters. Theoretical predictions show good agreement with experimental leakage pressure profiles, available from a Nitrogen at cryogenic temperatures. Force coefficient predictions for two phase flow conditions show significant fluid compressibility effects, particularly for mixtures with low mass content of vapor. Under these conditions, an increase on direct stiffness and reduction of whirl frequency ratio are shown to occur. Prediction of such important effects will motivate experimental studies as well as a more judicious selection of the operating conditions for seals used in cryogenic turbomachinery.

Arauz, Grigory L.↗

Aeropropulsion Technology (APT). Task 23 - Stator Seal Cavity Flow Investigation

The focus of NASA Contract NAS3-25950 Task 23 was to numerically investigate the flow through an axial compressor inner-banded stator seal cavity. The Allison/NASA developed ADPAC code was used to obtain all flow predictions. Flow through a labyrinth stator seal cavity of a high-speed compressor was modeled by coupling the cavity flow path and the main flow path of the compressor. A grid resolution study was performed to guarantee adequate grid spacing was used. Both unsteady rotor-stator-rotor interactions and steady-state isolated blade calculations were performed with and without the seal cavity present. A parameterized seal cavity study of the high-speed stator seal cavity collected a series of solutions for geometric variations. The parameter list included seal tooth gap, cavity depth, wheel speed, radial mismatch of hub flowpath, axial trench gap, hub corner treatments, and land edge treatments. Solution data presented includes radial and pitchwise distributions of flow variables and particle traces describing the flow character.

Heidegger, N. J.↗

Seal Materials Compatible with the Electroplating Solvent Used in Constellation-X Mirrors

The existing gasket seals used in electroplating of the Constellation-X mirrors are difficult to assemble, and the current seal material is hydrophobic and too thick. The combination of the above problems result in: 1) non-uniform plating; 2) defect sites such as pits on the mirror edges; 3) "bear claws" on the edges of the mandrels and mirrors causing difficulties in shell-mirror separations; and 4) leakage of the plating solution past the seals into the mandrel causing chemical etching of the mandrel interior. This paper reports the results of this summer study in searching for alternate seal materials chemically compatible with the electroplating solvent. Fifteen common elastomeric rubber seal materials made-by Parker Seals were investigated including butyl, ethylene propylene, fluorosilicone, nitrile, Viton fluorocarbon, and silicone. Test results showed that Viton fluorocarbon compounds as a group were superior to the other tested compounds for chemical compatibility with the plating bath.

Pei, Xiong-Skiba↗

Numerical Simulation of Flow, Pressure and Motion of Front Back Fingers in a Two Rows Finger Seal

This proposal fits within the programmatic long-term development direction for turbine engine seals of the Seal Team of the Mechanical Component Branch. The intended work concerns the further development of the Finger Seal concept which is a compliant passive-adaptive seal meant to mitigate (and eventually replace) the shortcomings of the entire class of rigid seals used today (labyrinth, honeycomb, mechanical face seals) in the gas turbines and compressors,

Braun, M. Jack↗

Shuttle Primary Reaction Control Subsystem Thruster Fuel Valve Pilot Seal Extrusion: A Failure Correlation

Pilot operated valves (POVs) are used to control the flow of hypergolic propellants monomethylhydrazine (fuel) and nitrogen tetroxide (oxidizer) to the Shuttle orbiter Primary Reaction Control Subsystem (PRCS) thrusters. The POV incorporates a two-stage design: a solenoid-actuated pilot stage, which in turn controls a pressure-actuated main stage. Isolation of propellant supply from the thruster chamber is accomplished in part by a captive polytetrafluoroethylene (PTFE) pilot seal retained inside a Custom 455.1 stainless steel cavity. Extrusion of the pilot seal restricts the flow of fuel around the pilot poppet, thus impeding or preventing the main valve stage from opening. It can also prevent the main stage from staying open with adequate force margin, particularly if there is gas in the main stage actuation cavity. During thruster operation on-orbit, fuel valve pilot seal extrusion is commonly indicated by low or erratic chamber pressure or failure of the thruster to fire upon command (Fail-Off). During ground turnaround, pilot seal extrusion is commonly indicated by slow gaseous nitrogen (GN2) main valve opening times (greater than 38 ms) or slow water main valve opening response times (greater than 33 ms). Poppet lift tests and visual inspection can also detect pilot seal extrusion during ground servicing; however, direct metrology on the pilot seat assembly provides the most quantitative and accurate means of identifying extrusion. Minimizing PRCS fuel valve pilot seal extrusion has become an important issue in the effort to improve PRCS reliability and reduce associated life cycle costs.

Waller, Jess↗

Compliant Foil Seal Investigations

Room temperature testing of an 8.5 inch diameter foil seal was conducted in the High Speed, High Temperature Turbine Seal Test Rig at the NASA Glenn Research Center. The seal was operated at speeds up to 30,000 rpm and pressure differentials up to 75 psid. Seal leakage and power loss data will be presented and compared to brush seal performance. The failure of the seal and rotor coating at 30,000 rpm and 15 psid will be presented and future development needs discussed.

Proctor, Margaret↗

NASA Glenn's Seals Group Inaugurated a New State-of-the-Art High-Temperature Test Rig

The NASA Glenn Research Center is developing advanced control surface seals and propulsion system seals for future space and launch vehicles. To evaluate new seal designs, the Glenn Seals Team recently inaugurated a new state-of-the-art high temperature seal test facility. The Hot Compression/Hot Scrub Rig can perform either high-temperature seal-compression tests or scrub tests at temperatures of up to 3000 F by using different combinations of test fixtures made of monolithic silicon carbide (Hexoloy alpha-SiC), as shown in the following figures. For lower temperature tests (up to 1500 F), Inconel X-750 test fixturing can be used.

DeMange, Jeffrey J.↗

Causes and Mitigation of Fuel Pilot Operated Valve Pilot Seal Extrusion in Space Shuttle Orbiter Primary RCS Thrusters

Extrusion of a polytetrafluoroethylene (PTFE) pilot seal located in the Space Shuttle Orbiter Primary Reaction Control Subsystem (PRCS) thruster fuel valve has been implicated in 68 ground and on-orbit fuel valve failures. A rash of six extrusion-related in-flight anomalies over a six-mission span from December 2001 to October 2002 led to heightened activity at various NASA centers, and the formation of a multidisciplinary team to solve the problem. Empirical and theoretical approaches were used. For example, thermomechanical analysis (TMA) and exposure tests showed that some extrusion is produced by thermal cycling; however, a review of thruster service histories did not reveal a strong link between thermal cycling and extrusion. Calculations showed that the amount of observed extrusion often exceeded the amount allowed by thermally-induced stress relief. Failure analysis of failed hardware also revealed the presence of fuel-oxidizer reaction product (FORP) inside the fuel valve pilot seal cavity, and differential scanning calorimetry (DSC) showed that the FORP was intimately associated with the pilot seal material. Component-level exposure tests showed that FORP of similar composition could be produced by adjacent oxidizer valve leakage in the absence of thruster firing. Specific gravity data showed that extruded fuel valve pilot seals were less dense than new pilot seals or oxidizer valve pilot seals, indicating permanent modification of the PTFE occurred during service. It is concluded that some thermally-induced extrusion is unavoidable; however, oxidizer leakage-induced extrusion is mostly avoidable and can be mitigated. Several engineering level mitigation strategies are discussed.

Waller, Jess M.↗

High-Temperature Knitted Spring Tubes Improved for Structural Seal Applications

To meet the needs of current and future space vehicles, the NASA Glenn Research Center is developing advanced control surface seals. These seals are used to fill the gaps surrounding actuated structures, such as rudders and body flaps, to shield underlying lower temperature structures, such as mechanical actuators, from the hot gases encountered during atmospheric reentry. During previous testing, the current baseline seal design, which is used on the space shuttle as a thermal barrier and was selected as the rudder-fin seal on the X-38 crew return vehicle, exhibited significant permanent set following compression at 1900 F (see the following photograph). Decreased resiliency (springback) could prevent the seal from contacting both of the opposing sealing surfaces and allow the ingestion of damaging hot gases during reentry, which could have detrimental effects on vehicle subsystems.

Dunlap, Patrick H.↗

Users' Manual for Computer Code SPIRALI Incompressible, Turbulent Spiral Grooved Cylindrical and Face Seals

The SPIRALI code predicts the performance characteristics of incompressible cylindrical and face seals with or without the inclusion of spiral grooves. Performance characteristics include load capacity (for face seals), leakage flow, power requirements and dynamic characteristics in the form of stiffness, damping and apparent mass coefficients in 4 degrees of freedom for cylindrical seals and 3 degrees of freedom for face seals. These performance characteristics are computed as functions of seal and groove geometry, load or film thickness, running and disturbance speeds, fluid viscosity, and boundary pressures. A derivation of the equations governing the performance of turbulent, incompressible, spiral groove cylindrical and face seals along with a description of their solution is given. The computer codes are described, including an input description, sample cases, and comparisons with results of other codes.

Walowit, Jed A.↗

High Temperature Metallic Seal Development For Aero Propulsion and Gas Turbine Applications

A viewgraph presentation on metallic high temperature static seal development at NASA for gas turbine applications is shown. The topics include: 1) High Temperature Static Seal Development; 2) Program Review; 3) Phase IV Innovative Seal with Blade Alloy Spring; 4) Spring Design; 5) Phase IV: Innovative Seal with Blade Alloy Spring; 6) PHase IV: Testing Results; 7) Seal Seating Load; 8) Spring Seal Manufacturing; and 9) Other Applications for HIgh Temperature Spring Design

More, Greg↗

Investigations of Shuttle Main Landing Gear Door Environmental Seals

The Columbia Accident investigation Board (CAIB) requested an investigation into the MLG door seals. Initially, the MLG door seals were thought to have been a potential contributor to the loss of Columbia. These suspicions were later found to be untrue, but the seals remained as a cause for concern in future flights. MLG door seals comprised of thermal barrier and environmental seal. This study focuses on the environmental seal for the MLG door.

Finkbeiner, Joshua↗

An Evaluation of High Temperature Airframe Seals for Advanced Hypersonic Vehicles

High temperature seals are required for advanced hypersonic airframe applications. In this study, both spring tube thermal barriers and innovative wafer seal systems were evaluated under relevant hypersonic test conditions (temperatures, pressures, etc.) via high temperature compression testing and room temperature flow assessments. Thermal barriers composed of a Rene 41 spring tube filled with Saffil insulation and overbraided with a Nextel 312 sheath showed acceptable performance at 1500 F in both short term and longer term compression testing. Nextel 440 thermal barriers with Rene 41 spring tubes and Saffil insulation demonstrated good compression performance up to 1750 F. A silicon nitride wafer seal/compression spring system displayed excellent load performance at temperatures as high as 2200 F and exhibited room temperature leakage values that were only 1/3 those for the spring tube rope seals. For all seal candidates evaluated, no significant degradation in leakage resistance was noted after high temperature compression testing. In addition to these tests, a superalloy seal suitable for dynamic seal applications was optimized through finite element techniques.

DeMange, Jeffrey J.↗