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Topics covered include the AGT 101 engine test; compressor design modification; cold air turbine testing; Mod 1 alloy turbine rotor fabrication; combustion aspects; regenerator development; and thermal screening tests for ceramic materials. The foil gas bearings, rotor dynamics, and AGT controls and accessories are also considered.
A long lifetime Stirling cycle cryogenic cooler particularly adapted for space applications is described. It consists of a compressor section centrally aligned end to end with an expansion section, and respectively includes a reciprocating compressor piston and displacer radially suspended in interconnecting cylindrical housings by active magnetic bearings and has adjacent reduced clearance regions so as to be in noncontacting relationship therewith and wherein one or more of these regions operate as clearance seals. The piston and displacer are reciprocated in their housings by linear drive motors to vary the volume of respectively adjacent compression and expansion spaces which contain a gaseous working fluid and a thermal regenerator to effect Stirling cycle cryogenic cooling.
The method employs ferromagnetic or ferromagnetic elements, preferably of rare-earth based material, for example gadolinium, and preferably employs a regenerator. The steps comprise controlling the temperature and applied magnetic field of the element to cause the state of the element as represented on a temperature-magnetic entropy diagram repeatedly to traverse a loop. The loop may have a first portion of concurrent substantially isothermal or constant temperature and increasing applied magnetic field, a second portion of lowering temperature and constant applied magnetic field, a third portion of isothermal and decreasing applied magnetic field, and a fourth portion of increasing temperature and constant applied magnetic field. Other loops may be four sided, with, for example, two isotherms and two adiabats (constant entropy portions.
Cultural information is provided for a data base that will be used to select candidate crop species for a controlled ecological life support system (CELSS). Lists of food crops which will satisfy most nutritional requirements of humans and also fit within the scope of cultural restrictions that logically would apply to a closed, regenerating system were generated. Cultural and environmental conditions that will allow the most rapid production of edible biomass from candidate species in the shortest possible time are identified. Cultivars which are most productive in terms of edible biomass production by (CE) conditions, and which respond to the ever-closed approach to optimization realized by each shortened production cycle are selected. The experimental approach with lettuce was to grow the crop hydroponically in a growth chamber and to manipulate such variables as light level and duration, day/night temperature, and nutrient form and level in the solution culture.
Two advanced, high efficiency coal-fired power plants were designed, one utilizing a phosphoric acid fuel cell and one utilizing a molten carbonate fuel cell. Both incorporate a TRW Catalytic Hydrogen Process gasifier and regenerator. Both plants operate without an oxygen plant and without requiring water feed; they, instead, require makeup dolomite. Neither plant requires a shift converter; neither plant has heat exchangers operating above 1250 F. Both plants have attractive efficiencies and costs. While the molten carbonate version has a higher (52%) efficiency than the phosphoric acid version (48%), it also has a higher ($0.078/kWh versus $0.072/kWh) ten-year levelized cost of electricity. The phosphoric acid fuel cell power plant is probably feasible to build in the near term: questions about the TRW process need to be answered experimentally, such as weather it can operate on caking coals, and how effective the catalyzed carbon-dioxide acceptor will be at pilot scale, both in removing carbon dioxide and in removing sulfur from the gasifier.
Compressor development, turbine, combustion, regenerator system, gearbox/transmission, ceramic material and component development, foil gas bearings, bearings and seals, rotor dynamics development, and controls and accessories are discussed.
Development testing activities on the 1900 F-configuration ceramic parts were completed, 2070 F-configuration ceramic component rig and engine testing was initiated, and the conceptual design for the 2265 F-configuration engine was identified. Fabrication of the 2070 F-configuration ceramic parts continued, along with burner rig development testing of the 2070 F-configuration metal combustor in preparation for 1132 C (2070 F) qualification test conditions. Shakedown testing of the hot engine simulator (HES) rig was also completed in preparation for testing of a spin rig-qualified ceramic-bladed rotor assembly at 1132 C (2070 F) test conditions. Concurrently, ceramics from new sources and alternate materials continued to be evaluated, and fabrication of 2070 F-configuration ceramic component from these new sources continued. Cold spin testing of the critical 2070 F-configuration blade continued in the spin test rig to qualify a set of ceramic blades at 117% engine speed for the gasifier turbine rotor. Rig testing of the ceramic-bladed gasifier turbine rotor assembly at 108% engine speed was also performed, which resulted in the failure of one blade. The new three-piece hot seal with the nickel oxide/calcium fluoride wearface composition was qualified in the regenerator rig and introduced to engine operation wiwth marginal success.
A phenomenological Bingham plastic model has previously been shown to provide an adequate description of the collapse of impact craters. This paper demonstrates that the Bingham parameters may be derived from a model in which acoustic energy generated during excavation fluidizes the rock debris surrounding the crater. Experimental support for the theoretical flow law is presented. Although the Bingham yield stress cannot be computed without detailed knowledge of the initial acoustic field, the Bingham viscosity is derived from a simple argument which shows that it increases as the 3/2 power of crater diameter, consistent with observation. Crater collapse may occur in material with internal dissipation Q as low as 100, comparable to laboratory observations of dissipation in granular materials. Crater collapse thus does not require that the acoustic field be regenerated during flow.
Progress towards development of an air revitalization system (ARS) for spacecraft breathable atmosphere regeneration is assessed, and a preliminary design for a one-person ARS is described. The ARS is considered a necessary component of any permanently manned orbital station, and studies have demonstrated that penalties for expendable air supplies justify an ARS for missions longer than 40 days. CO2 must be removed and O2 returned along with N2, which can be extracted from hydrazine, with the H2 component returning to the operation of the CO2 reduction subsystem. An experimental ARS (ARX-1) features a cabin humidity control unit, a CO2 concentrator, an air-cooled CO2 reduction reactor, an oxygen generator (electrolysis), the hydrazine N2 generator, and a water handling unit. A 120-day test demonstrated one-button startup and 480 hr operation in a normal mode.
In advance of initial dynamometer testing of the AGT 100 engine, all prime components and subsystems were bench/rig tested. Included were compressor, combustor, turbines, regenerator, ceramic components, and electronic control system. Results are briefly reviewed. Initial engine buildup was completed and rolled-out for test cell installation in July 1982. Shakedown testing included motoring and sequential firing of the combustor's three fuel nozzles.
Metal bellows used to seal Vuilleumier and Stirling-cycle cryogenic coolers, replacing sliding seals that failed after only 3,000 hours of service. Metal bellows, incorporated in displacer design provide nonrubbing dynamic seal. Lifetime of cryogenic cooler no longer limited by loss of sealing material and by deterioration of regenerators due to clogging by seal debris.
Technical work on the design and effort leading to the testing of a 74.5 kW (100 hp) automotive gas turbine is described. The general effort was concentrated on building an engine for test starting in July. The buildup progressed with only routine problems and the engine was delivered to the test stand 9 July. In addition to the engine build effort, work continued in selected component areas. Ceramic turbine parts were built and tested. Burst tests of ceramic rotors show strengths are approaching that achieved in test bars; proof testing is required for acceptable strength ceramic vanes. Over 25 hours was accumulated on the combustor rig in three test modes: pilot nozzle only, start nozzle, and main nozzle operation. Satisfactory ignition was achieved for a wide range of starting speeds and the lean blowout limit was as low as 0.06 kg/b (0.14 lb/hr). Lean blowout was more a function of nozzle atomization than fuel/air ratio. A variety of cycle points were tested. Transition from start nozzle flow to main nozzle flow was done manually without difficulty. Regenerator parts were qualification tested without incident and the parts were assembled on schedule. Rig based performance matched first build requirements. Repeated failures in the harmonic drive gearbox during rig testing resulted in that concept being abandoned for an alternate scheme.
The concept of a rechargeable fuel cell (RFC) system is considered. A newer type of rechargeable battery, the nickel hydrogen (Ni-H2) battery, is also evaluated. A review was made of past studies which showed large variations in weight, cost, and efficiency. Hydrogen-bromine and hydrogen-chlorine regenerable fuel cells were studied, and were found to have a potential for higher energy storage efficiency then the hydrogen-oxygen system. A reduction of up to 15 percent in solar array size may be possible as a result. These systems are not yet developed, but further study of them is recommended.
A method for optimizing the design (shape of the displacer) of low power Stirling cryocoolers relative to the power required to operate the systems is described. A variational calculation which includes static conduction, shuttle and radiation losses, as well as regenerator inefficiency, was completed for coolers operating in the 300 K to 10 K range. While the calculations apply to tapered displacer machines, comparison of the results with stepped displacer cryocoolers indicates reasonable agreement.
The design of a triple expansion closed cycle Stirling cryocooler optimized for a cooling load of 50 mW at 10 K is described. The cooler was designed with the objectives of low power, low weight, compactness, low mechanical motion, low electromagnetic noise, and low output temperature fluctuations. The design employs a direct drive linear motion piston motor and a triple expansion free displacer. Piston motion is controlled by feedback from an optical position transducer. Mechanical vibrations are attenuated with a passive resonant counterbalance. Electromagnetic noise is attenuated with layered high permeability magnetic shielding. The regenerators move with the displacer within a thin titanium cold finger. The piston and displacer oscillate at 8.33 Hz on bearings and seals of reinforced Teflon. The cooler is designed to provide the desired 50 mW of cooling at 10 K with a power input of less than 100 W. The piston can be driven at a greater stroke to produce up to 200 mW of cooling with an input power of 250 W. A lead and copper cold tip heat exchanger will limit temperature fluctuations to within 0.01 K.
The design and test results of a thyristor based inverter/charger are discussed. A battery charger is included integral to the inverter by using a subset of the inverter power circuit components. The resulting charger provides electrical isolation between the vehicle propulsion battery and ac line and is capable of charging a 25 kWh propulsion battery in 8 hours from a 220 volt ac line. The integral charger employs the inverter commutation components at a resonant ac/dc isolated converter rated at 3.6 kW. Charger efficiency and power factor at an output power of 3.6 kW are 86% and 95% respectively. The inverter, when operated with a matching polyphase ac induction motor and nominal 132 volt propulsion battery, can provide a peak shaft power of 34 kW (45 ph) during motoring operation and 45 kW (60 hp) during regeneration. Thyristors are employed for the inverter power switching devices and are arranged in an input-commutated topology. This configuration requires only two thyristors to commutate the six main inverter thyristors. Inverter efficiency during motoring operation at motor shaft speeds above 450 rad/sec (4300 rpm) is 92-94% for output power levels above 11 KW (15 hp). The combined ac inverter/charger package weighs 47 kg (103 lbs).
A regenerable, three man preprototype solid amine, water desorbed (SAWD) CO2 removal and concentation subsystem was designed, fabricated, and successfully acceptance tested by Hamilton Standard. The preprototype SAWD incorporates a single solid amine canister to perform the CO2 removal function, an accumulator to provide the CO2 storage and delivery function, and a microprocessor which automatically controls the subsystem sequential operation and performance. The SAWD subsystem was configured to have a CO2 removal and CO2 delivery capability at the rate of 0.12 kg/hr (0.264 lb/hr) over the relative humidity range of 35 to 70%. The controller was developed to provide fully automatic control over the relative humidity range via custom software that was generated specifically for the SAWD subsystem. The preprototype SAWD subsystem demonstrated a total of 281 hours (208) cycles of operation during ten acceptance tests that were conducted over the 3 to 70% relative humidity range. This operation was comprised of 178 hours (128 cycles) in the CO2 overboard mode and 103 hours (80 cycles) in the CO2 reduction mode. The average CO2 removal/delivery rate met or exceeded the design specification rate of 0.12 kg/hr (0.254 lb/hr) for all ten of the acceptance tests.
The potential of flywheel systems for space stations using the Space Operations Center (SOC) as a point of reference is discussed. Comparisons with batteries and regenerative fuel cells are made. In the flywheel energy storage concept, energy is stored in the form of rotational kinetic energy using a spinning wheel. Energy is extracted from the flywheel using an attached electrical generator; energy is provided to spin the flywheel by a motor, which operates during sunlight using solar array power. The motor and the generator may or may not be the same device. Flywheel energy storage systems have a very good potential for use in space stations. This system can be superior to alkaline secondary batteries and regenerable fuel cells in most of the areas that are important in spacecraft applications. Of special impotance relative to batteries, are high energy density (lighter weight), longer cycle and operating life, and high efficiency which minimizes the amount of orbital makeup fuel required. In addition, flywheel systems have a long shelf life, give a precise state of charge indication, have modest thermal control needs, are capable of multiple discharges per orbit, have simple ground handling needs, and have the potential for very high discharge rate. Major disadvantages are noted.