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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Engine Power Turbine and Propulsion Pod Arrangement Study

A study has been conducted for NASA Glenn Research Center under contract NNC10BA05B, Task NNC11TA80T to identify beneficial arrangements of the turboshaft engine, transmissions and related systems within the propulsion pod nacelle of NASA's Large Civil Tilt-Rotor 2nd iteration (LCTR2) vehicle. Propulsion pod layouts were used to investigate potential advantages, disadvantages, as well as constraints of various arrangements assuming front or aft shafted engines. Results from previous NASA LCTR2 propulsion system studies and tasks performed by Boeing under NASA contracts are used as the basis for this study. This configuration consists of two Fixed Geometry Variable Speed Power Turbine Engines and related drive and rotor systems (per nacelle) arranged in tilting nacelles near the wing tip. Entry-into-service (EIS) 2035 technology is assumed for both the engine and drive systems. The variable speed rotor system changes from 100 percent speed for hover to 54 percent speed for cruise by the means of a two speed gearbox concept developed under previous NASA contracts. Propulsion and drive system configurations that resulted in minimum vehicle gross weight were identified in previous work and used here. Results reported in this study illustrate that a forward shafted engine has a slight weight benefit over an aft shafted engine for the LCTR2 vehicle. Although the aft shafted engines provide a more controlled and centered CG (between hover and cruise), the length of the long rotor shaft and complicated engine exhaust arrangement outweighed the potential benefits. A Multi-Disciplinary Analysis and Optimization (MDAO) approach for transmission sizing was also explored for this study. This tool offers quick analysis of gear loads, bearing lives, efficiencies, etc., through use of commercially available RomaxDESIGNER software. The goal was to create quick methods to explore various concept models. The output results from RomaxDESIGNER have been successfully linked to Boeing spreadsheets that generate gear tooth geometry in Catia 3D environment. Another initial goal was to link information from RomaxDESIGNER (such as hp, rpm, gear ratio) to populate Boeing's parametric weight spreadsheet and create an automated method to estimate drive system weight. This was only partially achieved due to the variety of weight models, number of manual inputs, and qualitative assessments required. A simplified weight spreadsheet was used with data inputs from RomaxDESIGNER along with manual inputs to perform rough weight calculations.

Robuck, Mark↗
NASA NTRS1964

Apparatus alters position of objects to facilitate demagnetization

An apparatus consisting of pulleys, a drive shaft and an inner compartment, in which components to be demagnetized are mounted, is constructed. Due to the speed ratio of the three frames, every point on a component in the inner compartment is cycled through an optimum locus in the demagnetization field.

Rinard, G.↗
NASA NTRS1989

Improved rotor response of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

A means of eliminating the subsynchronous rotor whirl encountered during the development testing of the high-pressure oxygen turbopump of the Space Shuttle Main Engine is proposed. The rotor response is improved by reducing the pump end bearing loads and adding damping between the rotor and housing. In the present method, the impeller annular seals are converted into damping seals and the second rotor critical speed is increased due to the added stiffness of the seal conversion and the stiffening of the rotor shaft.

Beatty, R. F.↗
NASA NTRS1995

Wave Journal Bearing. Part 2: Experimental Pressure Measurements and Fractional Frequency Whirl Threshold for Wave and Plain Journal Bearings

A new hydrodynamic bearing concept, the wave journal bearing, is being developed because it has better stability characteristics than plain journal bearings while maintaining similar load capacity. An analysis code to predict the steady state and dynamic performance of the wave journal bearing is also part of the development. To verify numerical predictions and contrast the wave journal bearing's stability characteristics to a plain journal bearing, tests were conducted at NASA Lewis Research Center using an air bearing test rig. Bearing film pressures were measured at 16 ports located around the bearing circumference at the middle of the bearing length. The pressure measurements for both a plain journal bearing and a wave journal bearing compared favorably with numerical predictions. Both bearings were tested with no radial load to determine the speed threshold for self-excited fractional frequency whirl. The plain journal bearing started to whirl immediately upon shaft start-up. The wave journal did not incur self-excited whirl until 800 to 900 rpm as predicted by the analysis. Furthermore, the wave bearing's geometry limited the whirl orbit to less than the bearing's clearance. In contrast, the plain journal bearing did not limit the whirl orbit, causing it to rub.

Walker, James F.↗
DOE OSTI2022

DESIGN AND TESTING OF A 275 BAR 700 DEGREE CELSIUS EXPANDER FOR AN INTEGRALLY GEARED SUPERCRITICAL CO2 COMPANDER

An integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale concentrated solar power (CSP) supercritical carbon dioxide (sCO2) plant application was designed, manufactured, and tested. The integrally-geared compander (IGC) developed for this application comprises multiple pinion shafts interacting through a single bull gear to create a compact package and utilize a lowcost, low-speed driver. The present work will detail the design of the high-pressure high-temperature expander casing on an integrally geared frame, and illustrate how the project successfully mitigated the risk of fatigue and creep while allowing for rapid thermal transients in the design. Furthermore, test data from the test campaign will be presented supporting the analysis. Test results also show temperature profiles during operation exceeding 720° Celsius.

wilkes, jason↗
NASA NTRS1976

Endurance and failure characteristics of main-shaft jet engine bearings at 3x10 to the 6th power DN

Groups of thirty 120-mm bore angular contact ball bearings were endurance tested at a speed of 12,000 and 25,000 rpm and a thrust load of 66 721 N. The bearings were manufactured from a single heat of VIM-VAR AISI M-50 steel. At 1.44X1 million and 3.0x1 million DN, 84 483 and 74 800 bearing test hours were accumulated, respectively. Test results were compared with similar bearings made from CVM AISI M-50 steel run under the same conditions. Bearing lives at speeds of 3x1 million DN with the VIM-VAR AISI M-50 steel were nearly equivalent to those obtained at lower speeds. A combined processing and material life factor of 44 was found for VIM-VAR AISI M-50 steel. Continuous running after a spall has occurred at 3.0x1 million DN can result in a destructive fracture of the bearing inner race.

Bamberger, E. N.↗
NASA NTRS1994

Planar rotational magnetic micromotors with integrated shaft encoder and magnetic rotor levitation

Deep x-ray lithography and electroplating may be combined to form a fabrication tool for micromechanical devices with large structural heights, to 500 micron, and extreme edge acuities, less than 0.1 micron-run-out per 100 micron of height. This process concept which originated in Germany as LIGA may be further extended by adding surface micromachining. This extension permits the fabrication of precision metal and plastic parts which may be assembled into three-dimensional micromechanical components and systems. The processing tool may be used to fabricate devices from ferromagnetic material such as nickel and nickel-iron alloys. These materials when properly heat treated exhibit acceptable magnetic behavior for current to flux conversion and marginal behavior for permanent magnet applications. The tool and materials have been tested via planar, magnetic, rotational micromotor fabrication. Three phase reluctance machines of the 6:4 configuration with 280 micron diameter rotors have been tested and analyzed. Stable rotational speeds to 34,000 rpm with output torques above 10 x 10(exp -9) N-m have been obtained. The behavior is monitored with integrated shaft encoders which are photodiodes which measure the rotor response. Magnetic levitation of the rotor via reluctance forces has been achieved and has reduced frictional torque losses to less than 1 percent of the available torque. The results indicate that high speed limits of these actuators are related to torque ripple. Hysteresis motors with magnetic bearings are under consideration and will produce high speed rotational machines with excellent sensor application potential.

Guckel, Henry↗
NASA NTRS1980

Flow Induced Spring Coefficients of Labyrinth Seals for Application in Rotor Dynamics

Flow induced aerodynamic spring coefficients of labyrinth seals are discussed and the restoring force in the deflection plane of the rotor and the lateral force acting perpendicularly to it are also considered. The effects of operational conditions on the spring characteristics of these components are examined, such as differential pressure, speed, inlet flow conditions, and the geometry of the labyrinth seals. Estimation formulas for the lateral forces due to shaft rotation and inlet swirl, which are developed through experiments, are presented. The utilization of the investigations is explained and results of stability calculations, especially for high pressure centrifugal compressors, are added. Suggestions are made concerning the avoidance of exciting forces in labyrinths.

Benckert, H.↗
NASA NTRS1981

The hydraulic windmill

An hydraulic windmill is described. It pumps pressurized oil from rotor shaft level to the ground where a motor generator produces electricity. Alternatively, the useful output may be heat. Rotor speed is governed by a flow valve. Over pressure, the result of high wind velocity, rotates the tail to move the rotor blades out-of-the-wind. Loss of oil pressure causes a brake to close as well as to swing the tail to its maximum distance from the rotor plane.

Browing, J. A.↗
NASA NTRS1985

Improved turbopump dynamics

A study was initiated to investigate the practicality of increasing rotor critical speeds by changes in manufacturing method. The technique would be to build a pump with an all laser welded shaft and case; such unit to be opened by laser cutting and rebuilt by rewelding the same surface. Use of a split casing, common in industry, would permit assembly of the rotor outside the case. A team was formed to perform the study; however, the work of the team was severely restricted by conflict with higher priority tasks. No manpower was available to evaluate alternate configurations. Thus, much of the synergetic effects of cohesive design modification was lost. Although very limited results were achieved, nothing was found to indicate that the method is not worth further investigation.

Kiefling, L.↗
NASA NTRS1985

Influence of design parameters on occurence of oil whirl

Oil whirl instability is a serious problem in oil lubricated journal bearings. The phenomenon is characterized by a subsynchronous vibration of the journal within the bush and is particularly apparent in turbogenerators, aeroengines and electric motors. A review is presented of previous papers on the subject of oil whirl, and a simple theory is described which was used to aid the design of an oil whirl test rig. Predictions of the onset of oil whirl made by the theory presented were found to agree with those of previous researchers. They showed that increasing the shaft flexibility, or the lubricant viscosity, and decreasing the bearing radial clearance tended to reduce the oil whirl onset speed thus making the system more unstable.

Ogrodnik, P. J.↗
NASA NTRS1987

Off-design analysis of counter-rotating propeller configurations

An analysis is conducted to determine whether the counterrotating propeller configuration maintains, and perhaps improves, its excellent performance in the off-design mode for the constant-speed or variable-pitch case. While the twist distribution is maintained, the blade angle is changed to absorb shaft horsepower as a constant rpm setting is maintained under varying freestream velocities. A relatively flat propeller efficiency curve is obtained for advance ratios of 1.5-5.0.

Korkan, K. D.↗
NASA NTRS2002

High-Speed, High-Temperature Finger Seal Test Results

Finger seals have significantly lower leakage rates than conventional labyrinth seals used in gas turbine engines and are expected to decrease specific fuel consumption by over 1 percent and to decrease direct operating cost by over 0.5 percent. Their compliant design accommodates shaft growth and motion due to thermal and dynamic loads with minimal wear. The cost to fabricate these finger seals is estimated to be about half the cost to fabricate brush seals. A finger seal has been tested in NASA's High Temperature, High Speed Turbine Seal Test Rig at operating conditions up to 1200 F, 1200 ft/s, and 75 psid. Static, performance and endurance test results are presented. While seal leakage and wear performance are acceptable, further design improvements are needed to reduce the seal power loss.

Proctor, Margaret P.↗
NASA NTRS1986

Load cell verification of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.

Beatty, R. F.↗
NASA NTRS1971

Concepts for a theoretical and experimental study of lifting rotor random loads and vibrations. Phase 5C: Development of experimental methods

Test equipment which was built and the calibration tests are described. The test equipment consists of a two-bladed rotor of 16-in. diameter, the blades of which are elastically hinged in flapping. The feathering shaft of the blades can be harmonically rotated with the help of a cam mechanism located inside the hollow rotor shaft. The frequency range measured in the rotating system can be adjusted between 0 and 80 cps and the rotor speed between 0 and 40 cps. The test equipment is for measuring the flapping response of the blades to harmonic feathering excitation.

Hohenemser, K. H.↗
NASA NTRS1978

Evaluation of shuttle turbopump bearings

Because the high pressure turbopumps used on the space shuttle main engine (SSME) are high speed machines and rotor dynamics analysis of these units is very complicated, it was considered necessary to verify calculated turbomachinery shaft bearing loads by analysis of ball bearing load tracks. This report presents the methods used and the results of load track analysis on one set of bearings removed from a high pressure liquid oxygen turbopump which had been subjected to SSME static firing tests. This type of analysis was found useful in determining bearing operating conditions and for verifying rotor dynamics computer models.

Dufrane, K. F.↗
DOE OSTI2022

AN UPDATE ON THE STATUS OF A REDUCED FLOW TEST OF A 10MW 700⁰C SCO2 INTEGRALLY GEARED COMPANDER

In order to maintain viability as a future power-generating technology, concentrating solar power (CSP) must reduce its levelized cost of electricity (LCOE). One component of solving this problem is reducing the cost of the power block while simultaneously increasing the efficiency of the thermodynamic cycle. One disruptive technology that has the promise to accomplish this is supercritical CO2 based power cycles. These cycles are conceptually similar to steam cycles; however, they have substantially smaller turbomachinery at equivalent power while also delivering more efficiency at turbine inlet temperatures of 500-700℃. This paper will summarize the current status of a US Department of Energy project to develop machinery to support a 10 MW sCO2 power cycle. The team of Southwest Research Institute® (SwRI®) and Hanwha Power Systems America, proposed to develop an integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale CSP supercritical carbon dioxide (sCO2) plant application. This integrally-geared compander (IGC) comprises multiple pinion shafts interconnected on a single bull gear to create a compact package, and utilizes a low-cost, low-speed driver. In addition, the integrally-geared architecture allows each pinion to operate at different rotational speeds to optimize performance and easily allow for inter-stage cooling and turbine re-heat to further enhance both stage and cycle efficiency. The close integration of all turbomachinery elements into a single integrally-geared (IG) machine creates a design that lends itself to power block modularization, which makes it suitable for waste heat recovery, fossil fuel power plants, and especially CSP applications.

14 SOLAR ENERGY↗
DOE OSTI2022

An Update on the Status of a Reduced Flow Test of a 10MW 700°C sCO2 Integrally Geared Compander

. In order to maintain viability as a future power-generating technology, concentrating solar power (CSP) must reduce its levelized cost of electricity (LCOE). One component of solving this problem is reducing the cost of the power block while simultaneously increasing the efficiency of the thermodynamic cycle. One disruptive technology that has the promise to accomplish this is supercritical CO2 based power cycles. These cycles are conceptually similar to steam cycles; however, they have substantially smaller turbomachinery at equivalent power while also delivering more efficiency at turbine inlet temperatures of 500-700 degrees Celsius. This paper will summarize the current status of a US Department of Energy project to develop machinery to support a 10 MW sCO2 power cycle. The team of Southwest Research Institute® (SwRI®) and Hanwha Power Systems America, proposed to develop an integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale concentrated solar power (CSP) supercritical carbon dioxide (sCO2) plant application. This integrally-geared compander (IGC) comprises multiple pinion shafts interconnected on a single bull gear to create a compact package, and utilizes a low-cost, low-speed driver. In addition, the integrally geared architecture allows each pinion to operate at different rotational speeds to optimize performance and easily allow for inter-stage cooling and turbine re-heat to further enhance both stage and cycle efficiency. The close integration of all turbomachinery elements into a single integrally-geared (IG) machine creates a design that lends itself to power block modularization, which makes it suitable for waste heat recovery, fossil fuel power plants, and especially CSP applications. As part of the commercialization of this technology, it is necessary to reduce risk by validation testing of key components. In the current work, the focus is developing a test loop to enable safe testing of the main compressor stage across a wide range of operating conditions, and to validate the mechanical integrity of the turbine at full pressure, temperature, and speed. Developing a test loop for sCO2 requires balancing a number of design alternatives that impact cost, lead time, safety, and performance. The current work discusses the design process for the reduced flow test loop for the compander, and supporting documentation supporting the viability of the test loop

wilkes, jason↗