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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

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 of 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.

Ballistic Impact↗

Towards Flange-to-Flange Turbopump Simulations for Liquid Rocket Engines

The primary objective of this research is to support the design of liquid rocket systems for the Advanced Space Transportation System. Since the space launch systems in the near future are likely to rely on liquid rocket engines, increasing the efficiency and reliability of the engine components is an important task. One of the major problems in the liquid rocket engine is to understand fluid dynamics of fuel and oxidizer flows from the fuel tank to plume. Understanding the flow through the entire turbopump geometry through numerical simulation will be of significant value toward design. This will help to improve safety of future space missions. One of the milestones of this effort is to develop, apply and demonstrate the capability and accuracy of 3D CFD methods as efficient design analysis tools on high performance computer platforms. The development of the MPI and MLP versions of the INS3D code is currently underway. The serial version of INS3D code is a multidimensional incompressible Navier-Stokes solver based on overset grid technology. INS3D-MPI is based on the explicit massage-passing interface across processors and is primarily suited for distributed memory systems. INS3D-MLP is based on multi-level parallel method and is suitable for distributed-shared memory systems. For the entire turbopump simulations, moving boundary capability and an efficient time-accurate integration methods are build in the flow solver. To handle the geometric complexity and moving boundary problems, overset grid scheme is incorporated with the solver that new connectivity data will be obtained at each time step. The Chimera overlapped grid scheme allows subdomains move relative to each other, and provides a great flexibility when the boundary movement creates large displacements. The performance of the two time integration schemes for time-accurate computations is investigated. For an unsteady flow which requires small physical time step, the pressure projection method was found to be computationally efficient since it does not require any subiterations procedure. It was observed that the artificial compressibility method requires a fast convergence scheme at each physical time step in order to satisfy incompressibility condition. This was obtained by using a GMRES-ILU(0) solver in our computations. When a line-relaxation scheme was used, the time accuracy was degraded and time-accurate computations became very expensive. The current geometry for the LOX boost turbopump has various rotating and stationary components, such as inducer, stators, kicker, hydrolic turbine, where the flow is extremely unsteady. Figure 1 shows the geometry and computed surface pressure of the inducer. The inducer and the hydrolic turbine rotate in different rotational speed.

Kiris, Cetin↗

ACTS 118x Final Report High-Speed TCP Interoperability Testing

With the recent explosion of the Internet and the enormous business opportunities available to communication system providers, great interest has developed in improving the efficiency of data transfer using the Transmission Control Protocol (TCP) of the Internet Protocol (IP) suite. The satellite system providers are interested in solving TCP efficiency problems associated with long delays and error-prone links. Similarly, the terrestrial community is interested in solving TCP problems over high-bandwidth links. Whereas the wireless community is interested in improving TCP performance over bandwidth constrained, error-prone links. NASA realized that solutions had already been proposed for most of the problems associated with efficient data transfer over large bandwidth-delay links (which include satellite links). The solutions are detailed in various Internet Engineering Task Force (IETF) Request for Comments (RFCs). Unfortunately, most of these solutions had not been tested at high-speed (155+ Mbps). Therefore, the NASA's ACTS experiments program initiated a series of TCP experiments to demonstrate scalability of TCP/IP and determine how far the protocol can be optimized over a 622 Mbps satellite link. These experiments were known as the 118i and 118j experiments. During the 118i and 118j experiments, NASA worked closely with SUN Microsystems and FORE Systems to improve the operating system, TCP stacks. and network interface cards and drivers. We were able to obtain instantaneous data throughput rates of greater than 520 Mbps and average throughput rates of 470 Mbps using TCP over Asynchronous Transfer Mode (ATM) over a 622 Mbps Synchronous Optical Network (SONET) OC12 link. Following the success of these experiments and the successful government/industry collaboration, a new series of experiments. the 118x experiments. were developed.

Ivancic, William D.↗

The E3 combustors: Status and challenges

The design, fabrication, and initial testing of energy efficient engine combustors, developed for the next generation of turbofan engines for commercial aircraft, are described. The combustor designs utilize an annular configuration with two zone combustion for low emissions, advanced liners for improved durability, and short, curved-wall, dump prediffusers for compactness. Advanced cooling techniques and segmented construction characterize the advanced liners. Linear segments are made from castable, turbine-type materials.

Sokolowski, D. E.↗

National plan to enhance aviation safety through human factors improvements

The purpose of this section of the plan is to establish a development and implementation strategy plan for improving safety and efficiency in the Air Traffic Control (ATC) system. These improvements will be achieved through the proper applications of human factors considerations to the present and future systems. The program will have four basic goals: (1) prepare for the future system through proper hiring and training; (2) develop a controller work station team concept (managing human errors); (3) understand and address the human factors implications of negative system results; and (4) define the proper division of responsibilities and interactions between the human and the machine in ATC systems. This plan addresses six program elements which together address the overall purpose. The six program elements are: (1) determine principles of human-centered automation that will enhance aviation safety and the efficiency of the air traffic controller; (2) provide new and/or enhanced methods and techniques to measure, assess, and improve human performance in the ATC environment; (3) determine system needs and methods for information transfer between and within controller teams and between controller teams and the cockpit; (4) determine how new controller work station technology can optimally be applied and integrated to enhance safety and efficiency; (5) assess training needs and develop improved techniques and strategies for selection, training, and evaluation of controllers; and (6) develop standards, methods, and procedures for the certification and validation of human engineering in the design, testing, and implementation of any hardware or software system element which affects information flow to or from the human.

Foushee, Clay↗

Damage Accumulation and Failure of Plasma-Sprayed Thermal Barrier Coatings under Thermal Gradient Cyclic Conditions

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. A fundamental understanding of the sintering and thermal cycling induced delamination of thermal barrier coating systems under engine-like heat flux conditions will potentially help to improve the coating temperature capability. In this study, a test approach is established to emphasize the real-time monitoring and assessment of the coating thermal conductivity, which can initially increase under the steady-state high temperature thermal gradient test due to coating sintering, and later decrease under the thermal gradient cyclic test due to coating cracking and delamination. Thermal conductivity prediction models have been established for a ZrO2-(7- 8wt%)Y2O3 model coating system in terms of heat flux, time, and testing temperatures. The coating delamination accumulation is then assessed based on the observed thermal conductivity response under the combined steady-state and cyclic thermal gradient tests. The coating thermal gradient cycling associated delaminations and failure mechanisms under simulated engine heat-flux conditions will be discussed in conjunction with the coating sintering and fracture testing results.

Zhu, Dongming↗

Improving cost efficiency in large programs

This paper examines the question of cost, from the birth of a program to its conclusion, particularly from the point of view of large multi-center programs, and suggests how to avoid some of the traps and pitfalls. Emphasis is given to cost in the systems engineering process, but there is an inevitable overlap with program management. (The terms systems engineering and program management have never been clearly defined.) In these days of vast Federal budget deficits and increasing overseas competition, it is imperative that we get more for each research and development dollar. This is the only way we will retain our leadership in high technology and, in the long run, our way of life.

Hodge, John D.↗

Testing Efficiency Improved by Addition of Remote Access Control Room

The NASA Lewis Research Center's Remote Access Control Room (RACR) uses off-the-shelf video conferencing software integrated with existing facility data systems to provide access to the test data by networking from virtually anywhere in the country. The system allows research engineers in remote locations to participate in tests and monitor data in real time just as if they were present in the control room.

Source record↗

Firmware Development Improves System Efficiency

Most manufacturing processes require physical pointwise positioning of the components or tools from one location to another. Typical mechanical systems utilize either stop-and-go or fixed feed-rate procession to accomplish the task. The first approach achieves positional accuracy but prolongs overall time and increases wear on the mechanical system. The second approach sustains the throughput but compromises positional accuracy. A computer firmware approach has been developed to optimize this point wise mechanism by utilizing programmable interrupt controls to synchronize engineering processes 'on the fly'. This principle has been implemented in an eddy current imaging system to demonstrate the improvement. Software programs were developed that enable a mechanical controller card to transmit interrupts to a system controller as a trigger signal to initiate an eddy current data acquisition routine. The advantages are: (1) optimized manufacturing processes, (2) increased throughput of the system, (3) improved positional accuracy, and (4) reduced wear and tear on the mechanical system.

Chern, E. James↗

Advanced subsonic transport propulsion

A brief review of the current NASA Energy Efficient Engine (E(3)) Project is presented. Included in this review are the factors that influenced the design of these turbofan engines and the advanced technology incorporated in them to reduce fuel consumption and improve environmental characteristics. In addition, factors such as the continuing spiral in fuel cost, that could influence future aircraft propulsion systems beyond those represented by the E(3) engines, are also discussed. Advanced technologies that will address these influencing factors and provide viable future propulsion systems are described. The potential importance of other propulsion system types, such as geared fans and turboshaft engines, is presented.

Nored, D. L.↗

Component research for future propulsion systems

The factors affecting the helicopter market for the past, present, and future are reviewed. Acquisition cost, mission reliability, life cycle cost and civil and military aspects are reviewed. The potential for advanced vehicle configurations with substantial improvements in energy efficiency, operating economics, and characteristics to satisfy the demands of the future market are identified. Advanced propulsion systems required to support these vehicle configurations and the component technology for the engine systems are discussed. The selection of components in areas of economics and efficiency is considered.

Walker, C. L.↗

Evaluation of Spacecraft Shielding Effectiveness for Radiation Protection

The potential for serious health risks from solar particle events (SPE) and galactic cosmic rays (GCR) is a critical issue in the NASA strategic plan for the Human Exploration and Development of Space (HEDS). The excess cost to protect against the GCR and SPE due to current uncertainties in radiation transmission properties and cancer biology could be exceedingly large based on the excess launch costs to shield against uncertainties. The development of advanced shielding concepts is an important risk mitigation area with the potential to significantly reduce risk below conventional mission designs. A key issue in spacecraft material selection is the understanding of nuclear reactions on the transmission properties of materials. High-energy nuclear particles undergo nuclear reactions in passing through materials and tissue altering their composition and producing new radiation types. Spacecraft and planetary habitat designers can utilize radiation transport codes to identify optimal materials for lowering exposures and to optimize spacecraft design to reduce astronaut exposures. To reach these objectives will require providing design engineers with accurate data bases and computationally efficient software for describing the transmission properties of space radiation in materials. Our program will reduce the uncertainty in the transmission properties of space radiation by improving the theoretical description of nuclear reactions and radiation transport, and provide accurate physical descriptions of the track structure of microscopic energy deposition.

Cucinotta, Francis A.↗

Experimental Performance Evaluation of a Supersonic Turbine for Rocket Engine Applications

In order to mitigate the risk of rocket propulsion development, efficient, accurate, detailed fluid dynamics analysis and testing of the turbomachinery is necessary. To support this requirement, a task was developed at NASA Marshall Space Flight Center (MSFC) to improve turbine aerodynamic performance through the application of advanced design and analysis tools. These tools were applied to optimize a supersonic turbine design suitable for a reusable launch vehicle (RLV). The hot gas path and blading were redesigned-to obtain an increased efficiency. The goal of the demonstration was to increase the total-to- static efficiency of the turbine by eight points over the baseline design. A sub-scale, cold flow test article modeling the final optimized turbine was designed, manufactured, and tested in air at MSFC s Turbine Airflow Facility. Extensive on- and off- design point performance data, steady-state data, and unsteady blade loading data were collected during testing.

Snellgrove, Lauren M.↗

Commercial Cargo Derivative Study of the Advanced Hybrid Wing Body Configuration with Over-Wing Engine Nacelles

LM has leveraged our partnership with the Air Force Research Laboratory (AFRL) and NASA on the advanced hybrid wing body (HWB) concept to develop a commercial freighter which addresses the NASA Advanced Air Transport Technology (AATT) Project goals for improved efficiency beyond 2025. The current Air Force Research Laboratory (AFRL) Revolutionary Configurations for Energy Efficiency (RCEE) program established the HWB configuration and technologies needed for military transports to achieve aerodynamic and fuel efficiencies well beyond the commercial industry's most modern designs. This study builds upon that effort to develop a baseline commercial cargo aircraft and two HWB derivative commercial cargo aircraft to quanitify the benefit of the HWB and establish a technology roadmap for further development.

Hooker, John R.↗

Installed F/A-18 inlet flow calculations at 30 degrees angle-of-attack: A comparative study

NASA Lewis is currently engaged in a research effort as a team member of the High Alpha Technology Program (HATP) within NASA. This program utilizes a specially equipped F/A-18, the High Alpha Research Vehicle (HARV), in an ambitious effort to improve the maneuverability of high-performance military aircraft at low subsonic speed, high angle of attack conditions. The overall objective of the Lewis effort is to develop inlet technology that will ensure efficient airflow delivery to the engine during these maneuvers. One part of the Lewis approach utilizes computational fluid dynamics codes to predict the installed performance of inlets for these highly maneuverable aircraft. Full Navier-Stokes (FNS) calculations on the installed F/A-18 inlet at 30 degrees angle of attack, 0 degrees yaw, and a freestream Mach number of 0.2 have been obtained in this study using an algebraic turbulence model with two grids (original and revised). Results obtained with the original grid were used to determine where further grid refinements and additional geometry were needed. In order to account properly for the external effects, the forebody, leading edge extension (LEX), ramp, and wing were included with inlet geometry. In the original grid, the diverter, LEX slot, and leading edge flap were not included due to insufficient geometry definition, but were included in a revised grid. In addition, a thin-layer Navier-Stokes (TLNS) code is used with the revised grid and the numerical results are compared to those obtained with the FNS code. The TLNS code was used to evaluate the effects on the solution using a code with more recent CFD developments such as upwinding with TVD schemes versus central differencing with artificial dissipation. The calculations are compared to a limited amount of available experimental data. The predicted forebody/fuselage surface static pressures compared well with data of all solutions. The predicted trajectory of the vortex generated under the LEX was different for each solution. These discrepancies are attributed to differences in the grid resolution and turbulence modeling. All solutions predict that this vortex is ingested by the inlet. The predicted inlet total pressure recoveries are lower than data and the distortions are higher than data. The results obtained with the revised grid were significantly improved from the original grid results. The original grid results indicated the ingested vortex migrated to the engine face and caused additional distortions to those already present due to secondary flow development. The revised grid results indicate that the ingested vortex is dissipated along the inlet duct inboard wall. The TLNS results indicate the flow at the engine face was much more distorted than the FNS results and is attributed to the pole boundary condition introducing numerical distortions into the flow field.

Smith, C. Frederic↗

Magnetic bearings: A key technology for advanced rocket engines?

For several years, active magnetic bearings (AMB) have demonstrated their capabilities in many fields, from industrial compressors to control wheel suspension for spacecraft. Despite this broad area, no significant advance has been observed in rocket propulsion turbomachinery, where size, efficiency, and cost are crucial design criteria. To this respect, Societe Europeenne de Propulsion (SEP) had funded for several years significant efforts to delineate the advantages and drawbacks of AMB applied to rocket propulsion systems. Objectives of this work, relative technological basis, and improvements are described and illustrated by advanced turbopump layouts. Profiting from the advantages of compact design in cryogenic environments, the designs show considerable improvements in engine life, performances, and reliability. However, these conclusions should still be tempered by high recurrent costs, mainly due to the space-rated electronics. Development work focused on this point and evolution of electronics show the possibility to decrease production costs by an order of magnitude.

Girault, J. PH.↗

Technology outlook for aviation

Growth projections for aviation technology are put forth for a quarter-century ahead. Three main trends envisaged are towards: great efficiency and economy and longer range and endurance for subsonic aircraft; new generations of short-range fixed-wing craft and rotorcraft with versatile applicability; supersonic and hypersonic speeds. Improvements in lift/drag ratio, specific fuel consumption, structural weight factor, aerodynamic improvements (laminar flow control, increased wing aspect ratio, drag reduction for specified lift, propulsion efficiency, higher bypass ratios, composite structures) are discussed along with V/STOL, controllable twist rotors, circulation control rotors, variable-cycle engines, and higher structural efficiencies.

Roberts, L.↗

Burner liner thermal/structural load modelling

The objective of this program is to develop a thermal data transfer computer program module for the burner liner thermal structural load modeling program. This will be accomplished by (1) reviewing existing methodologies for thermal data transfer and selecting three heat transfer codes for application in this program; (2) evaluating the selected codes to establish criteria for developing a computer program module to transfer thermal data from the heat transfer codes to selected stress analysis codes; (3) developing the automated thermal load transfer module; and (4) verifying and documenting the module. In aircraft turbine engine hot section components, cyclic thermal stresses are the most important damage mechanism. Consequently, accurate and reliable prediction of thermal loads is essential to improving durability. To achieve this goal, a considerable effort over the past 20 years has been devoted to the acquisition of engine temperature test data, as well as the development of accurate, reliable, and efficient computer codes for the prediction of steady state and transient temperatures and for the calculation of elastic and inelastic cyclic stresses and strains in hot section components. There is a need for continued development of these codes, because the availability of more accurate analysis techniques for complex configurations has enabled engine designers to use more sophisticated designs to achieve higher cycle efficiency and reduce weight.

Maffeo, R. J.↗