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NASA NTRS1989

Calculations of inlet distortion induced compressor flow field instability

Calculations of the onset of flow instability are carried out for low-speed multistage axial compressors operating with asymmetric inlet flow. The modeling of the fluid dynamic interaction between the spoiled and unspoiled sectors of the compressor is the most important feature of the calculation procedure. The calculations show that annulus average slope of the compressor pressure rise characteristic equal to zero is a useful approximate stability criterion for situations where the dynamics of the compressor flow field do not couple strongly to the compression system or the structure of the imposed distortion is not similar to that of the eigenmodes of the flow in the compressor annulus. This criterion is employed to investigate the relationship between the present model and the 'parallel compressor' model. Calculations are also presented for cases when compressor and compressor system are closely coupled, and situations in which the compressor is subjected to a rotating distortion. These first-of-a-kind computations, and the accompanying description of the physical mechanisms, show that the stability of the flow in the compressor can be adversely affected if the temporal or spatial structure of the distortion is such that resonant type responses can be evoked either from the compressor or from compressor/compression system interactions.

Chue, R.↗

NASA NTRS2001

Active Control of Rotating Stall Demonstrated for a Multistage Compressor With Inlet Distortion

Aircraft compressors can suffer debilitating consequences as a result of rotating stall and surge events caused by inlet distortions. This is particularly true of aircraft during takeoff, when the compressor is operating at peak performance close to the surge line. Significant research has been conducted by the NASA Glenn Research Center in the area of compressor stability enhancement through active and passive control methods. Most recently, an experiment was conducted at the Wright Patterson Air Force Base Research Laboratory on a two-stage fan with inlet guide vanes and inlet distortion. In this joint Small Business Innovation Research effort between Scientific Systems and Glenn, control of rotating stall was demonstrated in a multistage transonic fan. This twostage fan with inlet guide vanes was tested under clean and distorted inlet conditions. The compressor was also configured with a circumferential distortion screen capable of 180 of distortion and with 14 high-velocity injectors upstream of the first rotor. Twelve of these injectors could oscillate up to frequencies of 450 Hz. The additional two injectors were located next to each other and were used in concert with each other as a single, on/off, high-authority actuator. In a first test of injection in this multistage environment, 12 of the valves were opened 50 percent of their full stroke to assess steady injection through the compressor. This baseline injection is shown in the compressor characteristic of the following figure, and stall margin improvements are tracked from this baseline condition. The compressor was then tested with clean inlet conditions using 12 injectors and active control. Pressure disturbances were tracked before rotating stall, and a constant gain control scheme reduced the stalling mass flow by 10.8 percent over the baseline. With the distortion screen present in the inlet, a pole-zero cancellation control scheme was used to achieve a 6.4-percent decrease in stalling mass flow. These improvements also are shown in the figure. In a final experiment, actively controlled, high-frequency injection from the 12 valves was used in conjunction with the high-authority actuators. In this test, the stalling mass flow of the compressor was reduced by 27 percent as indicated in the graph. These results were obtained by injecting less than 2 percent of the total compressor throughflow into the rotor tip region via 14 injection ports. These results mark the first successful demonstration of actively controlled air injection as a stall-control strategy for multistage compressors operating at speeds typical of an actual gas turbine engine. A goal of continuing research is to determine the combination of air-injection parameters and control strategies that are most effective in providing stall control for both clean and distorted inlet flow conditions for multistage environments. Other goals include the demonstration of stall control at many locations along the core compressor and development and application of active stall control strategies that will be integral flightworthy components of onboard engine hardware.

VanSchalkwyk, Christian↗

NASA NTRS2004

Counterrotatable booster compressor assembly for a gas turbine engine

A counterrotatable booster compressor assembly for a gas turbine engine having a counterrotatable fan section with a first fan blade row connected to a first drive shaft and a second fan blade row axially spaced from the first fan blade row and connected to a second drive shaft, the counterrotatable booster compressor assembly including a first compressor blade row connected to the first drive shaft and a second compressor blade row interdigitated with the first compressor blade row and connected to the second drive shaft. A portion of each fan blade of the second fan blade row extends through a flowpath of the counterrotatable booster compressor so as to function as a compressor blade in the second compressor blade row. The counterrotatable booster compressor further includes a first platform member integral with each fan blade of the second fan blade row at a first location so as to form an inner flowpath for the counterrotatable booster compressor and a second platform member integral with each fan blade of the second fan blade row at a second location so as to form an outer flowpath for the counterrotatable booster compressor.

Moniz, Thomas Ory↗

NASA NTRS2010

Conceptual Design of a Two Spool Compressor for the NASA Large Civil Tilt Rotor Engine

This paper focuses on the conceptual design of a two spool compressor for the NASA Large Civil Tilt Rotor engine, which has a design-point pressure ratio goal of 30:1 and an inlet weight flow of 30.0 lbm/sec. The compressor notional design requirements of pressure ratio and low-pressure compressor (LPC) and high pressure ratio compressor (HPC) work split were based on a previous engine system study to meet the mission requirements of the NASA Subsonic Rotary Wing Projects Large Civil Tilt Rotor vehicle concept. Three mean line compressor design and flow analysis codes were utilized for the conceptual design of a two-spool compressor configuration. This study assesses the technical challenges of design for various compressor configuration options to meet the given engine cycle results. In the process of sizing, the technical challenges of the compressor became apparent as the aerodynamics were taken into consideration. Mechanical constraints were considered in the study such as maximum rotor tip speeds and conceptual sizing of rotor disks and shafts. The rotor clearance-to-span ratio in the last stage of the LPC is 1.5% and in the last stage of the HPC is 2.8%. Four different configurations to meet the HPC requirements were studied, ranging from a single stage centrifugal, two axi-centrifugals, and all axial stages. Challenges of the HPC design include the high temperature (1,560deg R) at the exit which could limit the maximum allowable peripheral tip speed for centrifugals, and is dependent on material selection. The mean line design also resulted in the definition of the flow path geometry of the axial and centrifugal compressor stages, rotor and stator vane angles, velocity components, and flow conditions at the leading and trailing edges of each blade row at the hub, mean and tip. A mean line compressor analysis code was used to estimate the compressor performance maps at off-design speeds and to determine the required variable geometry reset schedules of the inlet guide vane and variable stators that would result in the transonic stages being aerodynamically matched with high efficiency and acceptable stall margins based on user specified maximum levels of rotor diffusion factor and relative velocity ratio.

Veres, Joseph P.↗

NASA NTRS1948

Performance Investigations of a Large Centrifugal Compressor from an Experimental Turbojet Engine

An investigation was conducted on a large centrifugal compressor from an experimental turbojet engine to determine the performance of the compressor and to obtain fundamental information on the aerodynamic problems associated with large centrifugal-type compressors. The results of the research conducted on the compressor indicated that the compressor would not meet the desired engine-design air-flow requirements (78 lb/sec) because of an air-flow restriction in the vaned collector (diffuser). Revision of the vaned collector resulted in an increased air-flow capacity over the speed range and showed improved matching of the impeller and diffuser components. At maximum flow, the original compressor utilized approximately 90 percent of the available geometric throat area at the vaned-collector inlet and the revised compressor utilized approximately 94 percent, regardless of impeller speed. The ratio of the maximum weight flows of the revised and original compressors were less than the ratio of effective critical throat areas of the two compressors because of the large pressure losses in the impeller near the impeller inelt and the difference increased with an increase in impeller speed. In order to further increase the pressure ratio and maximum weight flow of the compressor, the impeller must be modified to eliminate the pressure losses therein.

Ginsburg, Ambrose↗

NASA NTRS2014

Modeling the Deterioration of Engine and Low Pressure Compressor Performance During a Roll Back Event Due to Ice Accretion

The main focus of this study is to apply a computational tool for the flow analysis of the engine that has been tested with ice crystal ingestion in the Propulsion Systems Laboratory (PSL) of NASA Glenn Research Center. A data point was selected for analysis during which the engine experienced a full roll back event due to the ice accretion on the blades and flow path of the low pressure compressor. The computational tool consists of the Numerical Propulsion System Simulation (NPSS) engine system thermodynamic cycle code, and an Euler-based compressor flow analysis code, that has an ice particle melt estimation code with the capability of determining the rate of sublimation, melting, and evaporation through the compressor blade rows. Decreasing the performance characteristics of the low pressure compressor (LPC) within the NPSS cycle analysis resulted in matching the overall engine performance parameters measured during testing at data points in short time intervals through the progression of the roll back event. Detailed analysis of the fan-core and LPC with the compressor flow analysis code simulated the effects of ice accretion by increasing the aerodynamic blockage and pressure losses through the low pressure compressor until achieving a match with the NPSS cycle analysis results, at each scan. With the additional blockages and losses in the LPC, the compressor flow analysis code results were able to numerically reproduce the performance that was determined by the NPSS cycle analysis, which was in agreement with the PSL engine test data. The compressor flow analysis indicated that the blockage due to ice accretion in the LPC exit guide vane stators caused the exit guide vane (EGV) to be nearly choked, significantly reducing the air flow rate into the core. This caused the LPC to eventually be in stall due to increasing levels of diffusion in the rotors and high incidence angles in the inlet guide vane (IGV) and EGV stators. The flow analysis indicating compressor stall is substantiated by the video images of the IGV taken during the PSL test, which showed water on the surface of the IGV flowing upstream out of the engine, indicating flow reversal, which is characteristic of a stalled compressor.

Veres, Joseph P.↗

NASA NTRS2014

Modeling the Deterioration of Engine and Low Pressure Compressor Performance During a Roll Back Event Due to Ice Accretion

Jorgenson, Philip C. E.↗

NASA NTRS1956

Aerodynamic Design of Axial-flow Compressors. Volume III

Chapters XI to XIII concern the unsteady compressor operation arising when compressor blade elements stall. The fields of compressor stall and surge are reviewed in Chapters XI and XII, respectively. The part-speed operating problem in high-pressure-ratio multistage axial-flow compressors is analyzed in Chapter XIII. Chapter XIV summarizes design methods and theories that extend beyond the simplified two-dimensional approach used previously in the report. Chapter XV extends this three-dimensional treatment by summarizing the literature on secondary flows and boundary layer effects. Charts for determining the effects of errors in design parameters and experimental measurements on compressor performance are given in Chapters XVI. Chapter XVII reviews existing literature on compressor and turbine matching techniques.

COMPRESSORS - PRESSURE RATIO↗

NASA NTRS2017

Computational Assessment of a 3-Stage Axial Compressor Which Provides Airflow to the NASA 11- by 11-Foot Transonic Wind Tunnel, Including Design Changes for Increased Performance

A 24 foot diameter 3-stage axial compressor powered by variable-speed induction motors provides the airflow in the closed-return 11- by 11-Foot Transonic Wind Tunnel (11-Foot TWT) Facility at NASA Ames Research Center at Moffett Field, California. The facility is part of the Unitary Plan Wind Tunnel, which was completed in 1955. Since then, upgrades made to the 11-Foot TWT such as flow conditioning devices and instrumentation have increased blockage and pressure loss in the tunnel, somewhat reducing the peak Mach number capability of the test section. Due to erosion effects on the existing aluminum alloy rotor blades, fabrication of new steel rotor blades is planned. This presents an opportunity to increase the Mach number capability of the tunnel by redesigning the compressor for increased pressure ratio. Challenging design constraints exist for any proposed design, demanding the use of the existing driveline, rotor disks, stator vanes, and hub and casing flow paths, so as to minimize cost and installation time. The current effort was undertaken to characterize the performance of the existing compressor design using available design tools and computational fluid dynamics (CFD) codes and subsequently recommend a new compressor design to achieve higher pressure ratio, which directly correlates with increased test section Mach number. The constant cross-sectional area of the compressor leads to highly diffusion factors, which presents a challenge in simulating the existing design. The CFD code APNASA was used to simulate the aerodynamic performance of the existing compressor. The simulations were compared to performance predictions from the HT0300 turbomachinery design and analysis code, and to compressor performance data taken during a 1997 facility test. It was found that the CFD simulations were sensitive to endwall leakages associated with stator buttons, and to a lesser degree, under-stator-platform flow recirculation at the hub. When stator button leakages were modeled, pumping capability increased by over 20 of pressure rise at design point due to a large reduction in aerodynamic blockage at the hub. Incorporating the stator button leakages was crucial to matching test data. Under-stator-platform flow recirculation was thought to be large due to a lack of seals. The effect of this recirculation was assessed with APNASA simulations recirculating 0.5, 1, and 2 of inlet flow about stators 1 and 2, modeled as axisymmetric mass flux boundary conditions on the hub before and after the vanes. The injection of flow ahead of the stators tended to re-energize the boundary layer and reduce hub separations, resulting in about 3 increased stall margin per 1 of inlet flow recirculated. In order to assess the value of the flow recirculation, a mixing plane simulation of the compressor which gridded the under-stator cavities was generated using the ADPAC CFD code. This simulation indicated that about 0.65 of the inlet flow is recirculated around each shrouded stator. This collective information was applied during the redesign of the compressor. A potential design was identified using HT0300 which improved overall pressure ratio by removing pre-swirl into rotor 1, replacing existing NASA 65 series rotors with double circular arc sections, and re-staggering rotors and the existing stators. The performance of the new design predicted by APNASA and HT0300 is compared to the existing design.

Turbomachinery↗

NASA NTRSDate not supplied

Clearance Sensitivity Mitigation in Small Core Compressors

As future aircraft become lighter and more aerodynamically efficient, thrust requirements will decrease, reducing the core size of the engine. Furthermore, in the pursuit of improved fuel burn, engine overall pressure ratio and bypass ratio will increase, further driving down engine core size. These drivers together mean that the core size, or corrected mass flow rate at the compressor exit, for future single-aisle aircraft applications will shrink below 3.0 lbm/s. Traditionally, this small core compressor size is in the domain of axi-centrifugal designs, machines that are typically less efficient and limited to pressure ratios of ~25 due to stress and thermomechanical fatigue in the centrifugal impeller. In this light, NASA, Pratt & Whitney and the Raytheon Technologies Research Center embarked upon a program to develop technologies to enable an all-axial high-pressure compressor with a core size below 3.0 lbm/s and an overall pressure ratio greater than 50. One of the challenges with an all-axial high-pressure compressor at this core size is the small span at the rear of the compressor. As core size is scaled down, the rotor tip clearances do not scale with span, leading to significant efficiency penalties. This paper documents a numerical and experimental effort to mitigate this penalty through design optimization and technology insertion, enabling an estimated 5 to 10% fuel burn reduction relative to 2020 best-in-class. The experimental program consisted of two builds of a high-speed rig: a baseline build and a second build to insert technology to manage large rotor tip gap/span ratios. The results demonstrated a reduction in the sensitivity of the compressor to large clearance ratios, which would be likely at the end-of-life of a small core application. The test campaign demonstrated that, with the insertion of technology, small core compressors can maintain a similar efficiency to current best-in-class large core size compressors. In addition to advancing the state-of-the-art of technology, the program also advanced the modeling standards for multistage compressors with large clearance-to-span ratios. The validation of this approach is described in the paper.

Axial Compressors↗

NASA NTRSDate not supplied

Clearance Sensitivity Mitigation in Small Core Compressors

As future aircraft become lighter and more aerodynamically efficient, thrust requirements will decrease, reducing the core size of the engine. Furthermore, in the pursuit of improved fuel burn, engine overall pressure ratio and bypass ratio will increase, further driving down engine core size. These drivers together mean that the core size, or corrected mass flow rate at the compressor exit, for future single-aisle aircraft applications will shrink below 3.0 lb/s. Traditionally, this small core compressor size is in the domain of axi-centrifugal designs, machines that are typically less efficient and limited to pressure ratios of ~25 due to stress and thermomechanical fatigue in the centrifugal impeller. In this light, NASA, Pratt & Whitney and the Raytheon Technologies Research Center embarked upon a program to develop technologies to enable an all-axial high-pressure compressor with a core size below 3.0 lb/s and an overall pressure ratio greater than 50. One of the challenges with an all-axial high-pressure compressor at this core size is the small span at the rear of the compressor. As core size is scaled down, the rotor tip clearances do not scale with span, leading to significant efficiency penalties. This paper documents a numerical and experimental effort to mitigate this penalty through design optimization and technology insertion, enabling an estimated 5 to 10% fuel burn reduction relative to 2020 best-in-class. The experimental program consisted of two builds of a high-speed rig: a baseline build and a second build to insert technology to manage large rotor tip gap/span ratios. The results demonstrated a reduction in the sensitivity of the compressor to large clearance ratios, which would be likely at the end-of-life of a small core application. The test campaign demonstrated that, with the insertion of technology, small core compressors can maintain a similar efficiency to current best-in-class large core size compressors. In addition to advancing the state-of-the-art of technology, the program also advanced the modeling standards for multistage compressors with large clearance-to-span ratios. The validation of this approach is described in the paper.

Axial Compressors↗

NASA NTRS1974

Flight-measured inlet pressure transients accompanying engine compressor surges on the F-111A airplane

Two-F-111A airplanes were subjected to conditions that caused engine compressor surges and accompanying duct hammershock pressure transients. Flight speed ranged from Mach 0.71 to Mach 2.23, and altitude varied from approximately 3200 meters to 14,500 meters. A wide range of compressor pressure ratios was covered. Stabilized free-stream, engine, and duct conditions were established before each compressor surge. Dynamic pressure instrumentation at the compressor face and in the duct recorded the pressure transients associated with the surges. Hammershock pressures were analyzed with respect to the stabilized conditions preceding the compressor surges. The hammershock transients caused large pressure rises at the compressor face and in the duct. Hammershock pressure ratios at the compressor face were not affected by free-stream Mach number or altitude but were functions of engine variables, such as compressor pressure ratio. The maximum hammershock pressure ratio of approximately 1.83 occurred at a compressor pressure ratio of approximately 21.7.

Nugent, J.↗

NASA NTRS1949

Performance of J33-A-21 and J33-A-23 Turbojet-Engine Compressors with Water Injection

As part of the performance investigation of compressors for the J33 turbojet engine, the A-21 model and the A-23 model with a 17- and a 34-blade impeller were operated with water injection at their respective design equivalent speeds of 11,500 and 11,750 rpm. Inlet conditions of pressure of 14 inches of mercury absolute and of ambient temperature correspond to those of the investigation of these models without water injection. The water-air ratio by weight ranged from 0.05 to 0.06. By the use of water injection, the peak pressure ratio of the A-21 compressor and the A-23 compressor with a 34-blade impeller increased approximately 0.38, whereas that of the A-23 compressor with a 17-blade impeller increased only 0.14. The decrease in maximum efficiency for the three compressors ranged from 0.12 to 0.14. The highest increase in maximum equivalent weight flow of air plus weight flow of water was 10.90 pounds per second obtained with the A-21 compressor. The increase in air weight flow alone was approximately 5.70 pounds per second for the A-21 compressor end the A-23, 17-blade compressor, which exceeded the increase of 3.15 pounds per second for the A-23; 34-blade compressor.

Beede, William L.↗

NASA NTRS2004

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗

NASA NTRS2013

Reliability and Maintainability Analysis of a High Air Pressure Compressor Facility

This paper discusses a Reliability, Availability, and Maintainability (RAM) independent assessment conducted to support the refurbishment of the Compressor Station at the NASA Langley Research Center (LaRC). The paper discusses the methodologies used by the assessment team to derive the repair by replacement (RR) strategies to improve the reliability and availability of the Compressor Station (Ref.1). This includes a RAPTOR simulation model that was used to generate the statistical data analysis needed to derive a 15-year investment plan to support the refurbishment of the facility. To summarize, study results clearly indicate that the air compressors are well past their design life. The major failures of Compressors indicate that significant latent failure causes are present. Given the occurrence of these high-cost failures following compressor overhauls, future major failures should be anticipated if compressors are not replaced. Given the results from the RR analysis, the study team recommended a compressor replacement strategy. Based on the data analysis, the RR strategy will lead to sustainable operations through significant improvements in reliability, availability, and the probability of meeting the air demand with acceptable investment cost that should translate, in the long run, into major cost savings. For example, the probability of meeting air demand improved from 79.7 percent for the Base Case to 97.3 percent. Expressed in terms of a reduction in the probability of failing to meet demand (1 in 5 days to 1 in 37 days), the improvement is about 700 percent. Similarly, compressor replacement improved the operational availability of the facility from 97.5 percent to 99.8 percent. Expressed in terms of a reduction in system unavailability (1 in 40 to 1 in 500), the improvement is better than 1000 percent (an order of magnitude improvement). It is worthy to note that the methodologies, tools, and techniques used in the LaRC study can be used to evaluate similar high value equipment components and facilities. Also, lessons learned in data collection and maintenance practices derived from the observations, findings, and recommendations of the study are extremely important in the evaluation and sustainment of new compressor facilities.

Safie, Fayssal M.↗

NASA NTRS2017

High Efficiency Centrifugal Compressor for Rotorcraft Applications

The report "High Efficiency Centrifugal Compressor for Rotorcraft Applications" documents the work conducted at UTRC under the NRA Contract NNC08CB03C, with cost share 2/3 NASA, and 1/3 UTRC, that has been extended to 4.5 years. The purpose of this effort was to identify key technical barriers to advancing the state-of-the-art of small centrifugal compressor stages; to delineate the measurements required to provide insight into the flow physics of the technical barriers; to design, fabricate, install, and test a state-of-the-art research compressor that is representative of the rear stage of an axial-centrifugal aero-engine; and to acquire detailed aerodynamic performance and research quality data to clarify flow physics and to establish detailed data sets for future application. The design activity centered on meeting the goal set outlined in the NASA solicitation-the design target was to increase efficiency at higher work factor, while also reducing the maximum diameter of the stage. To fit within the existing Small Engine Components Test Facility at NASA Glenn Research Center (GRC) and to facilitate component re-use, certain key design parameters were fixed by UTRC, including impeller tip diameter, impeller rotational speed, and impeller inlet hub and shroud radii. This report describes the design effort of the High Efficiency Centrifugal Compressor stage (HECC) and delineation of measurements, fabrication of the compressor, and the initial tests that were performed. A new High-Efficiency Centrifugal Compressor stage with a very challenging reduction in radius ratio was successfully designed, fabricated and installed at GRC. The testing was successful, with no mechanical problems and the running clearances were achieved without impeller rubs. Overall, measured pressure ratio of 4.68, work factor of 0.81, and at design exit corrected flow rate of 3 lbm/s met the target requirements. Polytropic efficiency of 85.5 percent and stall margin of 7.5 percent were measured at design flow rate and speed. The measured efficiency and stall margin were lower than pre-test CFD predictions by 2.4 percentage points (pt) and 4.5 pt, respectively. Initial impressions from the experimental data indicated that the loss in the efficiency and stall margin can be attributed to a design shortfall in the impeller. However, detailed investigation of experimental data and post-test CFD simulations of higher fidelity than pre-test CFD, and in particular the unsteady CFD simulations and the assessment with a wider range of turbulence models, have indicated that the loss in efficiency is most likely due to the impact of unfavorable unsteady impeller/diffuser interactions induced by diffuser vanes, an impeller/diffuser corrected flow-rate mismatch (and associated incidence levels), and, potentially, flow separation in the radial-to-axial bend. An experimental program with a vaneless diffuser is recommended to evaluate this observation. A subsequent redesign of the diffuser (and the radial-to-axial bend) is also recommended. The diffuser needs to be redesigned to eliminate the mismatching of the impeller and the diffuser, targeting a slightly higher flow capacity. Furthermore, diffuser vanes need to be adjusted to align the incidence angles, to optimize the splitter vane location (both radially and circumferentially), and to minimize the unsteady interactions with the impeller. The radial-to-axial bend needs to be redesigned to eliminate, or at least minimize, the flow separation at the inner wall, and its impact on the flow in the diffuser upstream. Lessons were also learned in terms of CFD methodology and the importance of unsteady CFD simulations for centrifugal compressors was highlighted. Inconsistencies in the implementation of a widely used two-equation turbulence model were identified and corrections are recommended. It was also observed that unsteady simulations for centrifugal compressors require significantly longer integration times than what is current practice in industry.

Centrifugal compressor↗

NASA NTRS2021

NASA High Efficiency, High OPR Capable Small Core Compressor

As future aircraft become lighter and more aerodynamically efficient, thrust requirements will decrease, reducing the core size of the engine. Furthermore, in the pursuit of improved fuel burn, engine overall pressure ratio and bypass ratio will increase, further driving down engine core size (core size being defined as high-pressure compressor [HPC] exit-corrected flow). These drivers together mean that the core size for future single-aisle aircraft applications will shrink below 3.0 lb/s. Traditionally, this small core compressor size is in the domain of axi-centrifugal designs, machines that are typically less efficient and limited to pressure ratios of ~25 due to stress and thermomechanical fatigue in the centrifugal impeller. In this light, NASA and Pratt & Whtiney (P&W) embarked upon a program to develop technologies to enable an all-axial high-pressure compressor with a core size below 3.0 lb/s and an overall pressure ratio greater than 50. The challenge with an all-axial high-pressure compressor at this core size is the small span at the rear of the compressor. As core size is scaled down, the rotor tip clearances, stator hub seal clearances, fillet sizes and leading edge thicknesses do not scale, leading to significant efficiency penalties. The goal of this program is to recover this lapse and realize the cycle benefits of small core size and high overall pressure ratio. The small core challenges described are mitigated through design optimization and technology insertion, enabling an estimated 5 to 10% fuel burn reduction relative to 2020 best-in-class. Three test rigs run at NASA Glenn Research Center evolved the small core design: a low-speed rig to vet technology and validate tools, and two high speeds rigs, the first to demonstrate an optimized meanline design and the second to validate technology to manage large rotor tip gaps. The efficiency improvement validated with these rigs has unlocked the small core design space, demonstrating that small core compressors can maintain a similar efficiency to current best-in-class large core size compressors. In addition to advancing the state-of-the-art of technology, the program has also advanced the modeling standards for multistage compressors with large clearance-to-span ratios. A best practice modeling standard was developed over the course of the program, incorporating learning from all three rig programs.

Axial Compressors↗

NASA NTRS2009

Compressor Study to Meet Large Civil Tilt Rotor Engine Requirements

A vehicle concept study has been made to meet the requirements of the Large Civil Tilt Rotorcraft vehicle mission. A vehicle concept was determined, and a notional turboshaft engine system study was conducted. The engine study defined requirements for the major engine components, including the compressor. The compressor design-point goal was to deliver a pressure ratio of 31:1 at an inlet weight flow of 28.4 lbm/sec. To perform a conceptual design of two potential compressor configurations to meet the design requirement, a mean-line compressor flow analysis and design code were used. The first configuration is an eight-stage axial compressor. Some challenges of the all-axial compressor are the small blade spans of the rear-block stages being 0.28 in., resulting in the last-stage blade tip clearance-to-span ratio of 2.4%. The second configuration is a seven-stage axial compressor, with a centrifugal stage having a 0.28-in. impeller-exit blade span. The compressors conceptual designs helped estimate the flow path dimensions, rotor leading and trailing edge blade angles, flow conditions, and velocity triangles for each stage.

Veres, Joseph P.↗