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At least 577 records · Page 32

Comparison of Performance Test Results to CFD and Structural Models of Non-Contacting Finger Seals

Performance tests of non-contacting finger seal designs were conducted at 300, 700, 922 K (70, 800 and 1200 F) at pressure differentials up to 517 kPa (75 psid) and surface speeds up to 366 m/s (1200 ft/s). Room temperature, static analysis of the seal was performed. A simplified CFD model was developed to examine pressure loads within the seal. Results from the CFD model were used as input to a finite element analysis model of a six-finger segment of the non-contacting finger seal. Examination of predicted deflections of individual components of the seal gives insight into the seal behavior. Wear patterns from testing verify the pattern of radial deflection. The models are used to predict maximum pressure differential capability of the seal and compared to experimental results. The CFD model slightly under-predicts the measured leakage flow factor, but has the same trend as the measured flow factor versus pressure differential.

Seals:Brush Seals↗

Acoustic Sensor Network for Planetary Exploration

This paper investigates the concept of an acoustic sensor network that can monitor a variety of geophysical processes occurring on other planetary bodies. In many cases sound is naturally omnidirectional and travels at known speeds which depend on the composition and density of the atmosphere. The differences in the time of flight of signals received by a distributed microphone network can be used to locate the source of the sound. We suggest this property is ideal for mobile planetary robots and can be used to expand the exploration envelope considerably by directing camera pointing or rover path planning thus extending beyond line-of-sight exploration. Acoustic signatures have been used in a variety of fields (e.g., sonar, heavy machinery) to identify and catalog sounds associated with a specific vessels and malfunctioning machinery. Our ears have cataloged hundreds of sounds and we continuously use these sounds both consciously and subconsciously to extract information about our surroundings. This paper investigates the use acoustic measurements on other planetary bodies that could be used to characterize specific environmental parameters such as rain droplet size, wind speed, thunder, or dust devil vortex diameter. The paper identified other important sound sources that are thought to occur on other bodies in our solar system include; booming or singing dunes, waves, rivers, streams, fluidfalls, geysers, hurricanes, tornados, ice flow, volcanoes, planetary quakes, avalanche, rock slides and ice cracking. In addition, this paper focused on issues associated with the development of appropriate sensors for the network including the specification of the sensitivity, frequency response, and directional response of each of the microphones in the network in order to aid in localization of sound sources. We also presented our initial development of the transducers for potential mission targets including Mars and Titan and investigated the use of signal processing techniques including windowing, time frequency plots and correlation techniques to resolve phase differences between sensors in the network to aid in localization. We also identified additional benefits of these sensor networks in that they could used as engineering sensors to diagnose mechanical malfunctions on a rover or lander actuators or mechanisms. We also noted that they could also enhance public outreach by adding sound to videos.

Malaska, Mike↗

NASA Engineering and Safety Center Technical Bulletin No. 14-03: COPV Mechanical Model Validation

Global and local deformation measurements should be incorporated into the composite overwrapped pressure vessel (COPV) design and analysis process to allow correlation of these measurements with finite element analysis (FEA) models. This correlation improves understanding of liner, liner/overwrap interface, and composite deformation response in COPVs. The improved accuracy reduces error in subsequent analyses, such as fracture, fatigue, and stress rupture that are critical for COPV qualification.

Composite Overwrap Pressure Vehicle↗

Controls for Electrified Aircraft Propulsion

Advanced electrified aircraft propulsion (EAP) concepts with integrated power, propulsion, and thermal systems require the development of equally sophisticated controllers to fly safe and efficient missions. Hybrid electric aircraft utilize electric machines mechanically coupled to the engine shafts to extract and insert power for a variety of purposes. Additionally, electric machines may drive propulsive fans pulling from a combination of on-board energy storage devices and engine extracted power. NASA’s investment in hybrid electric aircraft hardware-in-the-loop testing enables controls research on representative engine models using a novel emulation and scaling methodology. High-voltage, high-power electrical powertrain presents several technical risks at altitude. High-power requires high efficiency to minimize losses. Superconducting electric machines and power distribution research at NASA has identified key challenges with potential controls solutions. These risks necessitate the development of controllers robust to model uncertainty, disturbances, and fault conditions. System health management and fault detection schemes play an important role in a multi-layer controls approach that utilizes a supervisor which oversees inner loops for the highly coupled power, propulsion, and thermal systems. Such a supervisory controller enables coordinates energy transfer between engines, energy storage devices, electric machines, propulsors, and heat exchangers. Existing methods have shown an improvement in engine operability using the hybrid electric powertrain.

Halle E Buescher↗

Modal Test and Model Correlation of NASA Plum Brook Station Mechanical Vibration Facility Head Expander –Lessons Learned from the Perspective of an Early-Career Engineer

In preparation for the Sierra Nevada Corporation’s (SNC) Dream Chaser spacecraft vibration test campaign at the Mechanical Vibration Facility (MVF) at NASA Plum Brook Station (PBS) in Sandusky, Ohio, a test-verified model of MVF is needed in order to be able to perform accurate pretest analysis used for determining response limits and abort levels. MVF was designed to vibration test MPCV Orion and was used to perform the system level vibration test of the European Service Module Structural Test Article (E-STA) in 2016. MVF is comprised of an 18 ft diameter annulus table that is driven with sixteen hydraulic vertical actuator assemblies and four hydraulic horizontal actuator assemblies, which allow it to perform single axis vibration testing in the vertical axis and in each of the two orthogonal horizontal axes without the need for reconfiguring the test article. A head expander for the MVF Table has been designed and built that fills in the center opening providing a continuous flat mounting surface with a maximum diameter of 16.25feet that expands the vibration testing capabilities of MVF. The MVF Table with this head expander will be used during the SNC Dream Chaser spacecraft vibration test campaign. Therefore, a critical element in a test-verified model of the MVF will be a test correlated finite element model (FEM) of the head expander. To obtain this, engineers from the Structural Dynamics Lab (SDL) at NASA Glenn Research Center (GRC) in Cleveland, Ohio performed a modal pretest analysis, conducted a modal test in July 2019, and most recently correlated the head expander finite element model to the modal test data up to 300 Hz. From the initial test preparations to the final delivery of a correlated finite element model, all efforts mentioned were led by the same early-career engineers at NASA GRC. From the viewpoint of an early-career engineer, lessons learned about modal pretest analysis, modal testing, and finite element model correlation of the MVF Table expander head will be presented and discussed. This will include the importance of understanding the limitations of using uncorrelated finite element models in the modal pretest analysis and planning, the importance of orthogonality metrics in judging adequacy and accuracy of test mode shapes, and the importance of having the FEM match the as built hardware in the model correlation effort.

Emma L Pierson↗

Quiet engine design highlights

Three high performance fans were designed, built, and tested, accumulating 444 hours. All three fans are both aerodynamically and mechanically suitable for direct incorporation into engine applications. Two turbofan demonstrators to evaluate both low- and high-speed fan systems were also designed, built, and tested. All components and engine systems are demonstrating high reliability. These components have demonstrated advanced state-of-the-art in acoustics, aerodynamics, and mechanical design.

Koff, B. L.↗

Instrumentation Working Group Summary

The Instrumentation Working Group compiled a summary of measurement techniques applicable to gas turbine engine aerosol precursors and particulates. An assessment was made of the limits, accuracy, applicability, and technology readiness of the various techniques. Despite advances made in emissions characterization of aircraft engines, uncertainties still exist in the mechanisms by which aerosols and particulates are produced in the near-field engine exhaust. To adequately assess current understanding of the formation of sulfuric acid aerosols in the exhaust plumes of gas turbine engines, measurements are required to determine the degree and importance of sulfur oxidation in the turbine and at the engine exit. Ideally, concentrations of all sulfur species would be acquired, with emphasis on SO2 and SO3. Numerous options exist for extractive and non-extractive measurement of SO2 at the engine exit, most of which are well developed. SO2 measurements should be performed first to place an upper bound on the percentage of SO2 oxidation. If extractive and non-extractive techniques indicate that a large amount of the fuel sulfur is not detected as SO2, then efforts are needed to improve techniques for SO3 measurements. Additional work will be required to account for the fuel sulfur in the engine exhaust. Chemical Ionization Mass Spectrometry (CI-MS) measurements need to be pursued, although a careful assessment needs to be made of the sampling line impact on the extracted sample composition. Efforts should also be placed on implementing non-intrusive techniques and extending their capabilities by maximizing exhaust coverage for line-of-sight measurements, as well as development of 2-D techniques, where feasible. Recommendations were made to continue engine exit and combustor measurements of particulates. Particulate measurements should include particle size distribution, mass fraction, hydration properties, and volatile fraction. However, methods to ensure that unaltered samples are obtained need to be developed. Particulate speciation was also assigned a high priority for quantifying the fractions of carbon soot, PAH, refractory materials, metals, sulfates, and nitrates. High priority was also placed on performing a comparison of particle sizing instruments. Concern was expressed by the workshop attendees who routinely make particulate measurements about the variation in number density measured during in-flight tests by different instruments. In some cases, measurements performed by different groups of researchers during the same flight tests showed an order of magnitude variation. Second priority was assigned to measuring concentrations of odd hydrogen and oxidizing species. Since OH, HO2, H2O2, and O are extremely reactive, non-extractive measurements are recommended. A combination of absorption and fluorescence is anticipated to be effective for OH measurements in the combustor and at the engine exit. Extractive measurements of HO2 have been made in the stratosphere, where the ambient level of OH is relatively low. Use of techniques that convert HO2 to OH for combustor and engine exit measurements needs to be evaluated, since the ratio of HO2/OH may be 1% or less at both the combustor and engine exit. CI-MS might be a viable option for H2O2, subject to sampling line conversion issues. However, H2O2 is a low priority oxidizing species in the combustor and at the engine exit. Two candidates for atomic oxygen measurements are Resonance Enhanced Multi-Photon Ionization (REMPI) and Laser-Induced Fluorescence (LIF). Particulate measurement by simultaneous extractive and non-extractive techniques was given equal priority to the oxidizer measurements. Concern was expressed over the ability of typical ground test sampling lines to deliver an unaltered sample to a remotely located instrument. It was suggested that the sampling probe and line losses be checked out by attempting measurements using an optical or non-extractive technique immediately upstream of the sampling probe. This is a possible application for Laser Induced Incandescence (LII) as a check on the volume fraction of soot. Optical measurements of size distribution are not well developed for ultrafine particles less than about 20 nm in diameter, so a non-extractive technique for particulate size distribution cannot be recommended without further development. Carbon dioxide measurements need to be made to complement other extractive measurement techniques. CO2 measurements enable conversion of other species concentrations to emission indices. Carbon monoxide, which acts as a sink for oxidizing species, should be measured using non-extractive techniques. CO can be rapidly converted to CO2 in extractive probes, and a comparison between extractive and non-extractive measurements should be performed. Development of non-extractive techniques would help to assess the degree of CO conversion, and might be needed to improve the concentration measurement accuracy. Measurements of NO(x) will continue to be critical due to the role of NO and NO2 in atmospheric chemistry, and their influence on atmospheric ozone. Time-resolved measurements of temperature, velocity, and species concentrations were included on the list of desired measurement. Thermocouples are typically adequate for engine exit measurements. PIV and LDV are well established for obtaining velocity profiles. The techniques are listed in the accompanying table; are divided into extractive and non-extractive techniques. Efforts were made to include a measurement uncertainty for each technique. An assessment of the technology readiness was included.

Zaller, Michelle↗

Bulk Metallic Glasses and Composites for Optical and Compliant Mechanisms

Mechanisms are used widely in engineering applications due to their ability to translate force and movement. They are found in kinematic pairs, gears, cams, linkages, and in flexure mechanisms (also known as compliant mechanisms). Mechanisms and flexures are used widely in spacecraft design, especially in the area of optics, where precise positioning of telescope mirrors requires elastic flexing of elements. A compliant mechanism is generally defined as a flexible mechanism that uses an elastic body deformation to cause a displacement (such as positing a mirror). The mechanisms are usually constructed as a single monolithic piece of material, and contain thin struts to allow for large elastic bending with low input force. This creates the largest problem with developing precise mechanisms; they must be fabricated from a single piece of metal, but are required to have strict accuracy on their dimensions. They are generally required to have high strength, elasticity, and low coefficient of thermal expansion.

Hofmann, Douglas C.↗

High-Temperature Mechanical Tensile Testing of Unidirectional Sic/Sic Composites Using A Versatile Lamp Furnace

Silicon carbide (SiC) based ceramic matrix composites (CMCs) are of interest for high-temperature structural applications, including use in turbine engine components. To understand damage mechanisms and predict durability of these systems, in-depth knowledge of their behavior at ambient and high temperatures is necessary. A method for high temperature testing of SiC/SiC minicomposite specimens up to 1500oC in both tensile fast fracture and creep conditions to investigate their thermomechanical behavior will be presented. This method utilizes a novel radiation heat furnace, equipped with infrared lamps with ellipsoidal reflectors, to heat the specimen at the furnace center in user-defined atmospheres. The housing structure of the lamps allows for observation of the specimen during testing using optical methods and for conducting other experimental studies. The goal is to employ nondestructive health monitoring techniques in-situ, including acoustic emission (AE), electrical resistance (ER), and digital image correlation (DIC) to evaluate damage initiation and evolution in the minicomposite specimens during tensile testing. Results from mechanical testing and nondestructive techniques will be presented. Electron microscopy and X-ray micro-computed tomography were used to further characterize specimen damage after testing.

Aeronautics↗

Advancing Systems Engineering Excellence: The Marshall Systems Engineering Leadership Development Program

As NASA undertakes increasingly complex projects, the need for expert systems engineers and leaders in systems engineering is becoming more pronounced. As a result of this issue, the Agency has undertaken an initiative to develop more systems engineering leaders through its Systems Engineering Leadership Development Program; however, the NASA Office of the Chief Engineer has also called on the field Centers to develop mechanisms to strengthen their expertise in systems engineering locally. In response to this call, Marshall Space Flight Center (MSFC) has developed a comprehensive development program for aspiring systems engineers and systems engineering leaders. This presentation will summarize the two-level program, which consists of a combination of training courses and on-the-job, developmental training assignments at the Center to help develop stronger expertise in systems engineering and technical leadership. In addition, it will focus on the success the program has had in its pilot year. The program hosted a formal kickoff event for Level I on October 13, 2009. The first class includes 42 participants from across MSFC and Michoud Assembly Facility (MAF). A formal call for Level II is forthcoming. With the new Agency focus on research and development of new technologies, having a strong pool of well-trained systems engineers is becoming increasingly more critical. Programs such as the Marshall Systems Engineering Leadership Development Program, as well as those developed at other Centers, help ensure that there is an upcoming generation of trained systems engineers and systems engineering leaders to meet future design challenges.

Hall, Philip↗

Reliability and Maintainability Engineering - A Major Driver for Safety and Affordability

The United States National Aeronautics and Space Administration (NASA) is in the midst of an effort to design and build a safe and affordable heavy lift vehicle to go to the moon and beyond. To achieve that, NASA is seeking more innovative and efficient approaches to reduce cost while maintaining an acceptable level of safety and mission success. One area that has the potential to contribute significantly to achieving NASA safety and affordability goals is Reliability and Maintainability (R&M) engineering. Inadequate reliability or failure of critical safety items may directly jeopardize the safety of the user(s) and result in a loss of life. Inadequate reliability of equipment may directly jeopardize mission success. Systems designed to be more reliable (fewer failures) and maintainable (fewer resources needed) can lower the total life cycle cost. The Department of Defense (DOD) and industry experience has shown that optimized and adequate levels of R&M are critical for achieving a high level of safety and mission success, and low sustainment cost. Also, lessons learned from the Space Shuttle program clearly demonstrated the importance of R&M engineering in designing and operating safe and affordable launch systems. The Challenger and Columbia accidents are examples of the severe impact of design unreliability and process induced failures on system safety and mission success. These accidents demonstrated the criticality of reliability engineering in understanding component failure mechanisms and integrated system failures across the system elements interfaces. Experience from the shuttle program also shows that insufficient Reliability, Maintainability, and Supportability (RMS) engineering analyses upfront in the design phase can significantly increase the sustainment cost and, thereby, the total life cycle cost. Emphasis on RMS during the design phase is critical for identifying the design features and characteristics needed for time efficient processing, improved operational availability, and optimized maintenance and logistic support infrastructure. This paper discusses the role of R&M in a program acquisition phase and the potential impact of R&M on safety, mission success, operational availability, and affordability. This includes discussion of the R&M elements that need to be addressed and the R&M analyses that need to be performed in order to support a safe and affordable system design. The paper also provides some lessons learned from the Space Shuttle program on the impact of R&M on safety and affordability.

Safie, Fayssal M.↗

Investigation of performance deterioration of the CF6/JT9D, high-bypass ratio turbofan engines

The aircraft energy efficiency program within NASA is developing technology required to improve the fuel efficiency of commercial subsonic transport aricraft. One segment of this program includes engine diagnostics which is directed toward determining the sources and causes of performance deterioration in the Pratt and Whitney Aircraft JT9D and General Electric CF6 high-bypass ratio turbofan engines and developing technology for minimizing the performance losses. Results of engine performance deterioration investigations based on historical data, special engine tests, and specific tests to define the influence of flight loads and component clearances on performance are presented. The results of analysis of several damage mechanisms that contribute to performance deterioration such as blade tip rubs, airfoil surface roughness and erosion, and thermal distortion are also included. The significance of these damage mechanisms on component and overall engine performance is discussed.

Ziemianski, J. A.↗

Performance deterioration of commercial high-bypass ratio turbofan engines

The results of engine performance deterioration investigations based on historical data, special engine tests, and specific tests to define the influence of flight loads and component clearances on performance are presented. The results of analyses of several damage mechanisms that contribute to performance deterioration such as blade tip rubs, airfoil surface roughness and erosion, and thermal distortion are also included. The significance of these damage mechanisms on component and overall engine performance is discussed.

Mehalic, C. M.↗

Fracture mechanics and corrosion fatigue.

Review of the current state-of-the-art in fracture mechanics, particularly in relation to the study of problems in environment-enhanced fatigue crack growth. The usefulness of this approach in developing understanding of the mechanisms for environmental embrittlement and its engineering utility are discussed. After a brief review of the evolution of the fracture mechanics approach and the study of environmental effects on the fatigue behavior of materials, a study is made of the response of materials to fatigue and corrosion fatigue, the modeling of the mechanisms of the fatigue process is considered, and the application of knowledge of fatigue crack growth to the prediction of the high cycle life of unnotched specimens is illustrated.

Mcevily, A. J.↗

Controllability of Free-piston Stirling Engine/linear Alternator Driving a Dynamic Load

This paper presents the dynamic behavior of a Free-Piston Stirling Engine/linear alternator (FPSE/LA) driving a single-phase fractional horse-power induction motor. The controllability and dynamic stability of the system are discussed by means of sensitivity effects of variations in system parameters, engine controller, operating conditions, and mechanical loading on the induction motor. The approach used expands on a combined mechanical and thermodynamic formulation employed in a previous paper. The application of state-space technique and frequency domain analysis enhances understanding of the dynamic interactions. Engine-alternator parametric sensitivity studies, similar to those of the previous paper, are summarized. Detailed discussions are provided for parametric variations which relate to the engine controller and system operating conditions. The results suggest that the controllability of a FPSE-based power system is enhanced by proper operating conditions and built-in controls.

Kankam, M. David↗

Advanced Propfan Engine Technology (APET) definition study, single and counter-rotation gearbox/pitch change mechanism design

Single-rotation propfan-powered regional transport aircraft were studied to identify key technology development issues and programs. The need for improved thrust specific fuel consumption to reduce fuel burned and aircraft direct operating cost is the dominant factor. Typical cycle trends for minimizing fuel consumption are reviewed, and two 10,000 shp class engine configurations for propfan propulsion systems for the 1990's are presented. Recommended engine configurations are both three-spool design with dual spool compressors and free power turbines. The benefits of these new propulsion system concepts were evaluated using an advanced airframe, and results are compared for single-rotation propfan and turbofan advanced technology propulsion systems. The single-rotation gearbox is compared to a similar design with current technology to establish the benefits of the advanced gearbox technology. The conceptual design of the advanced pitch change mechanism identified a high pressure hydraulic system that is superior to the other contenders and completely external to the gearboxes.

Anderson, R. D.↗

Design Protocols and Analytical Strategies that Incorporate Structural Reliability Models

Ceramic matrix composites (CMC) and intermetallic materials (e.g., single crystal nickel aluminide) are high performance materials that exhibit attractive mechanical, thermal, and chemical properties. These materials are critically important in advancing certain performance aspects of gas turbine engines. From an aerospace engineers perspective the new generation of ceramic composites and intermetallics offers a significant potential for raising the thrust/weight ratio and reducing NO(sub x) emissions of gas turbine engines. These aspects have increased interest in utilizing these materials in the hot sections of turbine engines. However, as these materials evolve and their performance characteristics improve a persistent need exists for state-of-the-art analytical methods that predict the response of components fabricated from CMC and intermetallic material systems. This need provided the motivation for the technology developed under this research effort. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for 'graceful' rather than catastrophic failure. When loaded in the fiber direction these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Thus modeling efforts supported under this research effort have focused on predicting this sort of behavior. For single crystal intermetallics the issues that motivated the technology development involved questions relating to material behavior and component design. Thus the research effort supported by this grant had to determine the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; map a simplistic future strength envelope of the material; develop a statistically based reliability computer algorithm; verify the reliability model and computer algorithm-, and model stator vanes for rig tests. Thus establishing design protocols that enable the engineer to analyze and predict the mechanical behavior of ceramic composites and intermetallics would mitigate the prototype (trial and error) approach currently used by the engineering community. The primary objective of the research effort supported by this short term grant is the continued creation of enabling technologies for the macro-analysis of components fabricated from ceramic composites and intermetallic material systems. The creation of enabling technologies aids in shortening the product development cycle of components fabricated from the new high technology materials.

Duffy, Stephen F.↗

Design Protocols and Analytical Strategies that Incorporate Structural Reliability Models

Ceramic matrix composites (CMC) and intermetallic materials (e.g., single crystal nickel aluminide) are high performance materials that exhibit attractive mechanical, thermal and chemical properties. These materials are critically important in advancing certain performance aspects of gas turbine engines. From an aerospace engineer's perspective the new generation of ceramic composites and intermetallics offers a significant potential for raising the thrust/weight ratio and reducing NO(x) emissions of gas turbine engines. These aspects have increased interest in utilizing these materials in the hot sections of turbine engines. However, as these materials evolve and their performance characteristics improve a persistent need exists for state-of-the-art analytical methods that predict the response of components fabricated from CMC and intermetallic material systems. This need provided the motivation for the technology developed under this research effort. Continuous ceramic fiber composites exhibit an increase in work of fracture, which allows for "graceful" rather than catastrophic failure. When loaded in the fiber direction, these composites retain substantial strength capacity beyond the initiation of transverse matrix cracking despite the fact that neither of its constituents would exhibit such behavior if tested alone. As additional load is applied beyond first matrix cracking, the matrix tends to break in a series of cracks bridged by the ceramic fibers. Any additional load is born increasingly by the fibers until the ultimate strength of the composite is reached. Thus modeling efforts supported under this research effort have focused on predicting this sort of behavior. For single crystal intermetallics the issues that motivated the technology development involved questions relating to material behavior and component design. Thus the research effort supported by this grant had to determine the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; map a simplistic failure strength envelope of the material; develop a statistically based reliability computer algorithm, verify the reliability model and computer algorithm, and model stator vanes for rig tests. Thus establishing design protocols that enable the engineer to analyze and predict the mechanical behavior of ceramic composites and intermetallics would mitigate the prototype (trial and error) approach currently used by the engineering community. The primary objective of the research effort supported by this short term grant is the continued creation of enabling technologies for the macroanalysis of components fabricated from ceramic composites and intermetallic material systems. The creation of enabling technologies aids in shortening the product development cycle of components fabricated from the new high technology materials.

Duffy, Stephen F.↗