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Two nondestructive techniques were used to evaluate diffusion bond quality between a metal foil honeycomb and porous wireform substrate. The two techniques, cryographics and acousto-ultrasonics, are complementary in revealing variations of bond integrity and quality in shroud segments from an experimental aircraft turbine engine.
Cost benefit studies were conducted on six advanced materials and processes technologies applicable to commercial engines planned for production in the 1985 to 1990 time frame. These technologies consisted of thermal barrier coatings for combustor and high pressure turbine airfoils, directionally solidified eutectic high pressure turbine blades, (both cast and fabricated), and mixers, tail cones, and piping made of titanium-aluminum alloys. A fabricated titanium fan blisk, an advanced turbine disk alloy with improved low cycle fatigue life, and a long-life high pressure turbine blade abrasive tip and ceramic shroud system were also analyzed. Technologies showing considerable promise as to benefits, low development costs, and high probability of success were thermal barrier coating, directionally solidified eutectic turbine blades, and abrasive-tip blades/ceramic-shroud turbine systems.
A FORTRAN-IV computer program was developed for the calculation of the inviscid transonic/supersonic flow field in a fully three dimensional blade passage of an axial compressor rotor or stator. Rotors may have dampers (part span shrouds). MacCormack's explicit time marching method is used to solve the unsteady Euler equations on a finite difference mesh. This technique captures shocks and smears them over several grid points. Input quantities are blade row geometry, operating conditions and thermodynamic quanities. Output quantities are three velocity components, density and internal energy at each mesh point. Other flow quanities are calculated from these variables. A short graphics package is included with the code, and may be used to display the finite difference grid, blade geometry and static pressure contour plots on blade to blade calculation surfaces or blade suction and pressure surfaces. The flow in a low aspect ratio transonic compressor was analyzed and compared with high response total pressure probe measurements and gas fluorescence static density measurements made in the MIT blowdown wind tunnel. These comparisons show that the computed flow fields accurately model the measured shock wave locations and overall aerodynamic performance.
A space based orbital transfer vehicle (SBOTV) and ground based OTV's (GBOTV) are compared for debris protection, space based OTV maintenance provisions, flight performance, onorbit refueling, and launch and return operations. Debris protection has a severe impact on the SBOTV, while the penalty for the GBOTV is much less severe. A key technology issue is the protection capability of composite materials. Onorbit maintenance is critical for SBOTV. Reduction of losses during the various transfers is th maine problem with refueling a SBOTV. Zero-g propellant storage and transfer is an important technology area for SBOTV. A reusable shroud must be developed to return GBOTV's if a Shuttle derivative vehicle is used. The advantage of space basing lies in more efficient use of the launch vehicle. Since most of the mass going to LEO is OTV propellant, and the launches to deliver the SBOTV propellant are generally mass limited, substantially fewer launches are required to support the SBOTV.
A fast computer program, GRID3C, was developed to generate multilevel three dimensional, C type, periodic, boundary conforming grids for the calculation of realistic turbomachinery and propeller flow fields. The technique is based on two analytic functions that conformally map a cascade of semi-infinite slits to a cascade of doubly infinite strips on different Riemann sheets. Up to four consecutively refined three dimensional grids are automatically generated and permanently stored on four different computer tapes. Grid nonorthogonality is introduced by a separate coordinate shearing and stretching performed in each of three coordinate directions. The grids are easily clustered closer to the blade surface, the trailing and leading edges and the hub or shroud regions by changing appropriate input parameters. Hub and duct (or outer free boundary) have different axisymmetric shapes. A vortex sheet of arbitrary thickness emanating smoothly from the blade trailing edge is generated automatically by GRID3C. Blade cross sectional shape, chord length, twist angle, sweep angle, and dihedral angle can vary in an arbitrary smooth fashion in the spanwise direction.
An active clearance control system was developed which reduces fuel consumption and performance degradation. This system utilizes compressor discharge air during takeoff and fan discharge air during cruise to impinge on the shroud structure to improve the thermal response. The system was evaluated in component and engine tests. The test results demonstrated a performance improvement of 0.7 percent in cruise SFC.
An axial compressor is provided with a cooling air manifold surrounding a portion of the shroud, and means for bleeding air from the compressor to the manifold for selectively flowing it in a modulating manner axially along the outer side of the stator/shroud to cool and shrink it during steady state operating conditions so as to obtain minimum shroud/rotor clearance conditions. Provision is also made to selectively divert the flow of cooling air from the manifold during transient periods of operation so as to alter the thermal growth or shrink rate of the stator/shroud and result in adequate clearance with the compressor rotor.
A mathematical optimization procedure was developed for the structural tailoring of engine blades and was used to structurally tailor two engine fan blades constructed of composite materials without midspan shrouds. The first was a solid blade made from superhybrid composites, and the second was a hollow blade with metal matrix composite inlays. Three major computerized functions were needed to complete the procedure: approximate analysis with the established input variables, optimization of an objective function, and refined analysis for design verification.
A technique is described in which the longitudinal wind component at airports, measured by Doppler radar, is put through a Fourier transformation to produce an energy density spectrum. The result is multiplied by the aircraft response characteristics to produce quantitative data on aircraft performance in a wind shear situation. The Doppler radar measurements are made along the intended flight path. Two case studies, along a 3 deg approach path, are described from measurements in two modes: Lagrangian, where predictions were computed one range gate ahead of the plane, and Eulerian, where samples were measured instantaneously along the flight path. Wind data obtained every second were interpolated to fit a numerical model by using a cubic spline. Eulerian data were superior to Lagrangian data in terms of ranging, and nearly equal for wind speeds. Improvements in current 75% accuracy are noted to be possible with shrouded antennas to reduce sidelobes and use of Doppler radar with higher resolution to eliminate effects of small scale disturbances within the pulse volume.
A specially configured 16.6 foot (5.1 meter) Disc Gap Band (DGB) Spin Parachute has been designed, developed, integrated with a sounding rocket, and qualified by flight testing. Design requirements include (1) stable parachute should successfully deploy in the altitude region of 260,000 feet (80 kilometers) from a Super Arcas launch vehicle; (2) after deployment, parachute and payload spin rate should be greater than three rpm; (3) four electric field sensors should be mounted on parachute shroud lines and have provisions to be electrically connected to the suspended payload; and (4) time above 100,000 feet (30 kilometers) should exceed five minutes. The successful meeting of these requirements provided the first known high-altitude deployment of a Spin Parachute.
The augmentor wing consists of a main airfoil with a slotted trailing edge for blowing, and two smaller aft airfoils which shroud the jet. This configuration has been modeled for numerical simulation by a novel discretization procedure which generates four separate grids: three surface-oriented airfoil grids and one outer free-stream grid. Grid lines and slopes are continuous across boundaries, so grid overlap at common boundaries provides boundary information without interpolation. A two-dimensional unsteady thin-layer Navier-Stokes code is used to calculate the flow for the no-blowing case at freestream Mach number = 0.7, Re = 12,600.000, and angles-of-incidence = 1.05 deg. Qualitative agreement with experimental data indicates the utility of this procedure in the analysis of multi-element configurations.
Proprietary research conducted under the NASA-sponsored Engine Component Improvement program is shown to have advanced the state of such component technologies as thermal barrier coatings, ceramic seal systems, advanced turbine clearance control, and JT9D engine fan design. In addition, the tests conducted have demonstrated the advantages of updated cooling, sealing and aerodynamic designs in the high pressure turbine and compressor of the JT8D engine. These technological advances are being transferred to such novel engine configurations as the PW2037 and NASA Energy Efficient Engine. Attention is given to the results of the thermal coating refinement tests of convectively cooled vanes, and to the development of a single shroud fan design applicable to the JT9D and next-generation engines.
Project 3, the subject of this technical report, was structured toward the successful engine demonstration of an improved-efficiency, long-life, tip-seal system for turbine blades. The advanced tip-seal system was designed to maintain close operating clearances between turbine blade tips and turbine shrouds and, at the same time, be resistant to environmental effects including high-temperature oxidation, hot corrosion, and thermal cycling. The turbine blade tip comprised an environmentally resistant, activated-diffussion-bonded, monocrystal superalloy combined with a thin layer of aluminium oxide abrasive particles entrapped in an electroplated NiCr matrix. The project established the tip design and joint location, characterized the single-crystal tip alloy and abrasive tip treatment, and established the manufacturing and quality-control plans required to fully process the blades. A total of 171 blades were fully manufactured, and 100 were endurance and performance engine-tested.
A single stage fan and quarter stage booster were designed for the energy efficient engine. The fan has an inlet radius ratio of 0.342 and a specific flow rate of 208.9 Kg/S sq m (42.8 lbm/sec sq ft). The fan rotor has 32 medium aspect ratio (2.597) titanium blades with a partspan shroud at 55% blade height. The design corrected fan tip speed is 411.5 M/S (1350 ft/sec). The quarter stage island splits the total fan flow with approximately 22% of the flow being supercharged by the quarter stage rotor. The fan bypass ratio is 6.8. The core flow total pressure ratio is 1.67 and the fan bypass pressure ratio is 1.65. The design details of the fan and booster blading, and the fan frame and static structure for the fan configuration are presented.
Technology related to aircraft fuel mass - flowmeters was reviewed to determine what flowmeter types could provide 0.25%-of-point accuracy over a 50 to one range in flowrates. Three types were selected and were further analyzed to determine what problem areas prevented them from meeting the high accuracy requirement, and what the further development needs were for each. A dual-turbine volumetric flowmeter with densi-viscometer and microprocessor compensation was selected for its relative simplicity and fast response time. An angular momentum type with a motor-driven, spring-restrained turbine and viscosity shroud was selected for its direct mass-flow output. This concept also employed a turbine for fast response and a microcomputer for accurate viscosity compensation. The third concept employed a vortex precession volumetric flowmeter and was selected for its unobtrusive design. Like the turbine flowmeter, it uses a densi-viscometer and microprocessor for density correction and accurate viscosity compensation.
The National Transonic Facility (NTF) is a research wind tunnel capable of operation at temperatures down to 89K (160 R) and pressures up to 900,000 Pa (9 atmospheres) to achieve Reynolds numbers approaching 120,000,000. Wide temperature excursions combined with the precise alignment requirements of the tunnel aerodynamic surfaces imposed constraints on the mechanisms supporting the internal structures of the tunnel. The material selections suitable for this application were also limited. A general design philosophy of utilizing a single fixed point for each linear degree of freedom and guiding the expansion as required was adopted. These support systems allow thermal expansion to take place in a manner that minimizes the development of thermally induced stresses while maintaining structural alignment and resisting high aerodynamic loads. Typical of the support mechanisms are the preload brackets used in the fan shroud system and the Watts linkage used to support the upstream nacelle. The design of these mechanisms along with the basic design requirements and the constraints imposed by the tunnel system are discussed.
The high accuracy fuel flowmeter development program is described. A flightworthy meter that measures mass flowrate of aircraft fuels to within + or - 0.25% of reading over a 50:1 range of flow is developed. A study of measurement techniques to achieve this goal yielded three candidates: (1) a dual turbine flowmeter with density and viscosity compensation; (2) an angular momentum flowmeter with a motor-driven, spring-restrained turbine and viscosity shroud; and (3) a vortex precission flowmeter with density and viscosity compensation. An experimental study of each technique was completed and the first two candidates were selected for prototype development.
An advanced design, lightweight, fuse-quartz mirror of sandwich construction was evaluated for optical figure performance at cryogenic temperatures. A low temperature shroud was constructed with an integral mirror mount and interface to a cryostat for use in a vacuum chamber. The mirror was tested to 13 K. Cryogenic distortion of the mirror was measured interferometrically. Separate interferometry of the chamber window during the test permitted subtraction of the small window distortions from the data. Results indicate that the imaging performance of helium cooled, infrared telescopes will be improved using this type of mirror without correction of cryogenic distortion of the primary mirror.