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All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Erosion Coatings for High-Temperature Polymer Composites: A Collaborative Project With Allison Advanced Development Company

The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.

Sutter, James K.↗
NASA NTRS2005

Adaptive Technologies Developed and Demonstrated for Extending the Stable Operating Range of Compressors

The operational envelope of gas turbine engines is constrained by the stability limit of the compression system. The dangers of exceeding this limit are severe, with the potential for engine failure and loss of the aircraft. To avoid such failures, compressor designers provide an adequate stability (stall) margin in the compressor design to account for inlet distortions, degradation due to wear, throttle transients, and other factors that reduce compressor stability from the original design intent. In some cases, the required stall margin results in the compressor operating line being below the maximum efficiency potential of the compression system. Current approaches to increasing stability tend to decrease the efficiency of the compressor. The focus of this work is to increase the stall margin of compressors without decreasing their efficiency.

Hathaway, Michael D.↗
NASA NTRS2002

Fundamental Mixing and Combustion Experiments for Propelled Hypersonic Flight

The first experiment is a study of a coaxial jet discharging into stagnant laboratory air, with center jet of a mixture of 5% oxygen and 95% helium by volume and coflow jet of air. The exit flow pressure of both center-jet and coflow nozzles is 1 atmosphere. The presence of oxygen in the center jet is to allow the use of an oxygen flow-tagging technique (RELIEF4) to obtain non-intrusive velocity measurements. Both jets are nominally Mach 1.8, but, because of the greater speed of sound, the center jet velocity is more than twice that of the coflow. The mixing layer which forms between the center jet and the coflow near the nozzle exit is compressible, with a calculated convective Mach number of approximately 0.7. This geometry has several advantages: The streamwise development of the flow is generally dominated by turbulent stresses (rather than pressure forces), and thus calculations are sensitive to turbulence modeling. It includes features present in supersonic combustors, including a compressible mixing layer near the nozzle exit and a light-gas/air plume downstream. Since it is a free jet, it provides easy access for both optical instrumentation and probes. Since it is axisymmetric, it requires fewer experimental measurements to fully characterize, and calculations can be performed with more modest computer resources. However, weak shock waves formed at the nozzle exit strengthen and turn normal as they approach the axis, complicating the flow. Care is thus taken in the design of the facility to provide as near as possible to 1-D flow at the exit of both center and coflow nozzles, and to minimize the strength of waves generated at the nozzle exit. Results from this experiment are compared to CFD solutions obtained by VULCAN, a previously developed code used in engine analysis. The second experiment is a study of a supersonic combustor consisting of a diverging duct with single downstream-angled wall injector. Thus, the geometry is relatively simple and large regions of subsonic recirculating flow are avoided. The nominal entrance Mach number is 2 and the enthalpy of the test gas (hot air "simulant") is nominally that of Mach 7 flight. It was believed, on the basis of calculations performed that this would produce mixing-limited flow, that is to say, one for which chemical reaction to equilibrium proceeds at a much greater rate than mixing. It later proved that this was not the case. The primary experimental technique employed is coherent anti-Stokes Raman spectroscopy, known by its acronym CARS. The species probed is molecular nitrogen and the quantity measured is temperature. Intrusive probes, such as Pitot, total temperature, hot-wire, etc., are not used due to access difficulty and high heat flux in the combustor, and because they may alter the flow. CARS has several advantages over other optical methods. It is a relatively mature and well-understood technique. Signal levels are relatively high and the signal is in the form of a coherent (laser) beam that can be collected through small windows. Incoherent (non-CARS) interferences are rejected by spatial filtering.

Diskin, G. S.↗
NASA NTRS2022

Scientific Value of Including an Atmospheric Sample as Part of Mars Sample Return (MSR)

The Perseverance rover is meant to collect samples of the martian surface for eventual return to Earth. The headspace gas present over the solid samples within the sample tubes will be of significant scientific interest for what it reveals about the interactions of the solid samples with the trapped atmosphere and for what it will reveal about the martian atmosphere itself. However, establishing the composition of the martian atmosphere will require other dedicated samples. The headspace gas as the sole atmospheric sample is problematic for many reasons. The quantity of gas present within the sample tube volume is insufficient for many investigations, and there will be exchange between solid samples, headspace gas, and tube walls. Importantly, the sample tube materials and preparation were not designed for optimal Mars atmospheric gas collection and storage as they were not sent to Mars in a degassed evacuated state and have been exposed to both Earth's and Mars' atmospheres. Additionally, there is a risk of unconstrained seal leakage in transit back to Earth, which would allow fractionation of the sample (leak-out) and contamination (leak-in). The science return can be improved significantly (and, in some cases, dramatically) by adding one or more of several strategies listed here in increasing order of effectiveness and difficulty of implementation: (1) Having Perseverance collect a gas sample in an empty sample tube, (2) Collecting gas in a newly-designed, valved, sample-tube-sized vessel that is flown on either the Sample Fetch Rover (SFR) or the Sample Retrieval Lander (SRL), (3) Adding a larger (50-100 cc) dedicated gas sampling volume to the Orbiting Sample container (OS), (4) Adding a larger (50-100 cc) dedicated gas sampling volume to the OS that can be filled with compressed martian atmosphere.

Timothy D. Swindle↗
NASA NTRS1977

Compressibility measurement of fluid-system ullage

Portable self-contained instrument measures volume of free gas or air trapped in closed fluid systems, such as lubricating-oil lines or hydraulic brakes. In response to measurement readings, operator may use device to accurately add or withdraw fluid to or from system.

Dzienis, D. A.↗
NASA NTRS2009

Adiabatic Shock Capturing in Perfect Gas Hypersonic Flows

This paper considers the streamline-upwind Petrov/Galerkin (SUPG) method applied to the compressible Euler and Navier-Stokes equations in conservation-variable form. The spatial discretization, including a modified approach for interpolating the inviscid flux terms in the SUPG finite element formulation, is briefly reviewed. Of particular interest is the behavior of the shock capturing operator, which is required to regularize the scheme in the presence of strong, shock-induced gradients. A standard shock capturing operator which has been widely used in previous studies by several authors is presented and discussed. Specific modifications are then made to this standard operator which are designed to produce a more physically consistent discretization in the presence of strong shock waves. The actual implementation of the term in a finite dimensional approximation is also discussed. The behavior of the standard and modified scheme is then compared for several supersonic/hypersonic flows. The modified shock capturing operator is found to preserve enthalpy in the inviscid portion of the flowfield substantially better than the standard operator.

Kirk, Benjamin S.↗
NASA NTRS2020

Thermal Analysis, Compressibility, and Decomposition of Synthetic Bastnäsite-(La) to Lanthanum Oxyfluoride

Understanding basic material properties of rare earth element (REE) bearing minerals such as their phase stability and equations of state can assist in understanding how economically viable deposits might form. Bastnäsite is the most commonly mined REE bearing mineral. We synthesized the lanthanum-fluoride end member, bastnäsite-(La) (LaCO3F), and investigated its thermal behavior and decomposition products from 298 K to 1173 K under ambient pressure conditions through thermogravimetric analysis, differential scanning calorimetry, evolved gas analysis, and high temperature powder X-ray diffraction. We also investigated the compressibility of bastnäsite-(La) via single crystal X-ray diffraction in diamond anvil cells at an ambient temperature up to 11.3 GPa and from 4.9 GPa to 7.7 GPa up to 673 K. At ambient pressure, bastnäsite-(La) was stable up to 598 K in air, where it decomposed into CO2 and tetragonal γ-LaOF. Above 948 K, cubic α-LaOF is stable. High temperature X-ray diffraction data were used to fit the Fei thermal equation of state and the thermal expansion coefficient α(sub 298) for all three materials. Bastnäsite-(La) was fit from 298 K to 723 K with V(sub 0) = 439.82 Å(exp 3), α(sub 298) = 4.32 × 10(exp -5) K(exp -1), a(sub 0) = −1.68 × 10(exp -5) K(exp -1), a(sub 1) = 8.34 × 10(exp -8) K(exp -1), and a(sub 2) = 3.126 K(exp -1). Tetragonal γ-LaOF was fit from 723 K to 948 K with V(sub 0) = 96.51 Å(exp 3), α(sub 298) = 2.95×10(exp -4) K(exp -1), a(sub 0) = −2.41×10(exp -5) K(exp -1), a(sub 1) = 2.42×10(exp -7) K(exp -1), and a(sub 2) = 41.147 K(exp -1). Cubic α-LaOF was fit from 973 K to 1123 K with V(sub 0) = 190.71 Å(exp 3), α(sub 298) = −1.12×10(exp -5) K(exp -1), a(sub 0) = 2.36×10(exp -4) K(exp -1), a(sub 1) = −1.73 × 10(exp -7) K(exp -1), and a(sub 2) = −17.362 K(exp -1). An ambient temperature third order Birch–Murnaghan equation of state was fit with V(sub 0) = 439.82 Å(exp 3), K(sub 0) = 105 GPa, and K’ = 5.58.

Bastnäsite↗
NASA NTRS2001

Study of Two-Dimensional Compressible Non-Acoustic Modeling of Stirling Machine Type Components

A two-dimensional (2-D) computer code was developed for modeling enclosed volumes of gas with oscillating boundaries. such as Stirling machine components. An existing 2-D incompressible flow computer code, CAST, was used as the starting point for the project. CAST was modified to use the compressible non-acoustic Navier-Stokes equations to model an enclosed volume including an oscillating piston. The devices modeled have low Mach numbers and are sufficiently small that the time required for acoustics to propagate across them is negligible. Therefore. acoustics were excluded to enable more time efficient computation. Background information about the project is presented. The compressible non-acoustic flow assumptions are discussed. The governing equations used in the model are presented in transport equation format. A brief description is given of the numerical methods used. Comparisons of code predictions with experimental data are then discussed.

Roy C. Tew, Jr↗
NASA NTRS1987

Controlled ecological life support systems; Proceedings of Workshop II of the 26th COSPAR Plenary Meeting, Toulouse, France, June 30-July 11, 1986

The present conference on the development status of Controlled Ecological Life Support Systems (CELSSs) discusses food production and gas exchange with the Spirulina blue-green alga, biomass recycling for greater energy efficiency in algal culture CELSSs, algal proteins for food processing in a CELSS, a CELSS with photosynthetic N2-fixing cyanobacteria, the NASA CELSS program, and vapor compression ditillation and membrane technology for water revitalization. Also discussed are a fundamental study of CELSS gas monitoring, the application of catalytic wet oxidation to CELSS, a large-scale perspective on ecosystems, Japanese CELSS research activities, the use of potatoes in bioregenerative life-support, wheat production in controlled environments, and a trickle water and feeding system in plant culture.

Macelroy, R. D.↗
NASA NTRS1993

An Experimental Parametric Study of Geometric, Reynolds Number, and Ratio of Specific Heats Effects in Three-Dimensional Sidewall Compression Scramjet Inlets at Mach 6

Since mission profiles for airbreathing hypersonic vehicles such as the National Aero-Space Plane include single-stage-to-orbit requirements, real gas effects may become important with respect to engine performance. The effects of the decrease in the ratio of specific heats have been investigated in generic three-dimensional sidewall compression scramjet inlets with leading-edge sweep angles of 30 and 70 degrees. The effects of a decrease in ratio of specific heats were seen by comparing data from two facilities in two test gases: in the Langley Mach 6 CF4 Tunnel in tetrafluoromethane (where gamma=1.22) and in the Langley 15-Inch Mach 6 Air Tunnel in perfect gas air (where gamma=1.4). In addition to the simulated real gas effects, the parametric effects of cowl position, contraction ratio, leading-edge sweep, and Reynolds number were investigated in the 15-Inch Mach 6 Air Tunnel. The models were instrumented with a total of 45 static pressure orifices distributed on the sidewalls and baseplate. Surface streamline patterns were examined via oil flow, and schlieren videos were made of the external flow field. The results of these tests have significant implications to ground based testing of inlets in facilities which do not operate at flight enthalpies.

Holland, Scott D.↗
NASA NTRS1977

Variational energy principle for compressible, baroclinic flow. 1: First and second variations of total kinetic action

The case of a cold gas in the absence of external force fields is considered. Since the only energy involved is kinetic energy, the total kinetic action (i.e., the space-time integral of the kinetic energy density) should serve as the total free-energy functional in this case, and as such should be a local minimum for all possible fluctuations about stable flow. This conjecture is tested by calculating explicit, manifestly covariant expressions for the first and second variations of the total kinetic action in the context of Lagrangian kinematics. The general question of the correlation between physical stability and the convexity of any action integral that can be interpreted as the total free-energy functional of the flow is discussed and illustrated for the cases of rectillinear and rotating shearing flows.

Schmid, L. A.↗
NASA NTRS1987

Thermomechanical behavior of plasma-sprayed ZrO2-Y2O3 coatings influenced by plasticity, creep and oxidation

Thermocycling of ceramic-coated turbomachine components produces high thermomechanical stresses that are mitigated by plasticity and creep but aggravated by oxidation, with residual stresses exacerbated by all three. These residual stresses, coupled with the thermocyclic loading, lead to high compressive stresses that cause the coating to spall. A ceramic-coated gas path seal is modeled with consideration given to creep, plasticity, and oxidation. The resulting stresses and possible failure modes are discussed.

Padovan, J.↗
NASA NTRS1987

A Navier-Stokes flow simulation of the Space Shuttle Main Engine Hot Gas Manifold

Incompressible viscous flow inside the turnaround duct, the fuel bowl, the transfer duct and the racetrack of the Space Shuttle Main Engine (SSME) Hot Gas Manifold (HGM) has been computed using the method of pseudo-compressibility together with an implicit, approximate-factorization algorithm. A multiple-zone method is used to make solution of flows in complex geometries easy. A model which predicts the pressure loading for the shield and the injector post arrangement without solving the complex flow field in the main injector region is proposed. The computed results show good qualitative agreement with experimental data.

Yang, Ruey-Jen↗
NASA NTRS1987

Thermomechanical behavior of plasma-sprayed ZrO2-Y2O3 coatings influenced by plasticity, creep, and oxidation

Thermocycling of ceramic-coated turbomachine components produces high thermomechanical stresses that are mitigated by plasticity and creep but aggravated by oxidation, with residual stresses exacerbated by all three. These residual stresses, coupled with the thermocyclic loading, lead to high compressive stresses that cause the coating to spall. A ceramic-coated gas path seal is modeled with consideration given to creep, plasticity, and oxidation. The resulting stresses and possible failure modes are discussed.

Padovan, J.↗