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At least 73 records · Page 4

Engine panel seals for hypersonic engine applications: High temperature leakage assessments and flow modelling

A critical mechanical system in advanced hypersonic engines is the panel-edge seal system that seals gaps between the articulating horizontal engine panels and the adjacent engine splitter walls. Significant advancements in seal technology are required to meet the extreme demands placed on the seals, including the simultaneous requirements of low leakage, conformable, high temperature, high pressure, sliding operation. In this investigation, the seal concept design and development of two new seal classes that show promise of meeting these demands will be presented. These seals include the ceramic wafer seal and the braided ceramic rope seal. Presented are key elements of leakage flow models for each of these seal types. Flow models such as these help designers to predict performance-robbing parasitic losses past the seals, and estimate purge coolant flow rates. Comparisons are made between measured and predicted leakage rates over a wide range of engine simulated temperatures and pressures, showing good agreement.

Steinetz, Bruce M.↗

Evaluation of an innovative high temperature ceramic wafer seal for hypersonic engine applications

A critical mechanical system in advanced hypersonic engines is the panel-edge seal system that seals gaps between the articulating engine panels and the adjacent engine splitter walls. Significant advancements in seal technology are required to meet the extreme demands placed on the seals, including the simultaneous requirements of low leakage, conformable, high temperature, high pressure, sliding operation. In this investigation, the design, development, analytical and experimental evaluation of a new ceramic wafer seal that shows promise of meeting these demands will be addressed. A high temperature seal test fixture was designed and fabricated to measure static seal leakage performance under engine simulated conditions. Ceramic wafer seal leakage rates are presented for engine-simulated air pressure differentials (up to 100 psi), and temperature (up to 1350 F), sealing both flat and distorted wall conditions, where distortions can be as large as 0.15 inches in only an 18 inch span. Seal leakage rates are low, meeting an industry-established tentative leakage limit for all combinations of temperature, pressure and wall conditions considered. A seal leakage model developed from externally-pressurized gas film bearing theory is also presented. Predicted leakage rates agree favorably with the measured data for nearly all conditions of temperature and pressure. Discrepancies noted at high engine pressure and temperature are attributed to thermally-induced, non-uniform changes in the size and shape of the leakage gap condition. The challenging thermal environment the seal must operate in places considerable demands on the seal concept and material selection. Of the many high temperature materials considered in the design, ceramics were the only materials that met the many challenging seal material design requirements. Of the aluminum oxide, silicon carbide, and silicon nitride ceramics considered in the material ranking scheme developed herein, the silicon nitride class of ceramics ranked the highest because of their high temperature strength; resistance to the intense heating rates; resistance to hydrogen damage; and good structural properties. Baseline seal feasibility has been established through the research conducted in this investigation. Recommendations for future work are also discussed.

Steinetz, Bruce M.↗

Advanced Seals and Secondary Airflow Systems for Allison AST

The author will present results obtained to date of a secondary flow study currently being conducted. The purpose of the study is to investigate and report all the ramifications of introducing advanced sealing technology into gas turbine engine secondary flow systems. In addition to detailed cost/benefit results we will also derive seal operational requirements which can be fed into a subsequent advanced seal development program. Using the current Allison AE3007 engine as a model/baseline we have examined 6 different advanced seal variations. We have settled on a design with 2 advanced seals which results n a savings of 2% in chargeable cooling. The introduction of these advanced seals has resulted in substantial changes to surrounding engine components which will be reported.

Munson, John↗

Aerosol Envelope Sealing of Existing Residences

This report explores the best methods for aerosol envelope sealing of unoccupied, existing residences and documents typical leakage reductions. The project consisted of three distinct efforts: (1) scaled field demonstrations of the sealing process, tracking from setup to sealing and cleanup, (2) laboratory testing of new sealants that dry clear, making them more appropriate for retrofit applications, and (3) BEopt™ (Building Energy Optimization Tool) modeling of the energy implications of the measured reductions in leakage. Overall, aerosol sealing performance in existing homes was effective, with an average leakage reduction of 47% across all 34 sites. Conventional approaches typically only produce leakage reductions of 25%–30%. The aerosol sealing technology could provide a process for existing homes and multifamily units to gain the benefits of a well-sealed home at a reasonable cost with minimal disruption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A Probabilistic Assessment of NASA Ultra-Efficient Engine Technologies for a Large Subsonic Transport

NASA's Ultra Efficient Engine Technology (UEET) program features advanced aeropropulsion technologies that include highly loaded turbomachinery, an advanced low-NOx combustor, high-temperature materials, intelligent propulsion controls, aspirated seal technology, and an advanced computational fluid dynamics (CFD) design tool to help reduce airplane drag. A probabilistic system assessment is performed to evaluate the impact of these technologies on aircraft fuel burn and NOx reductions. A 300-passenger aircraft, with two 396-kN thrust (85,000-pound) engines is chosen for the study. The results show that a large subsonic aircraft equipped with the UEET technologies has a very high probability of meeting the UEET Program goals for fuel-burn (or equivalent CO2) reduction (15% from the baseline) and LTO (landing and takeoff) NOx reductions (70% relative to the 1996 International Civil Aviation Organization rule). These results are used to provide guidance for developing a robust UEET technology portfolio, and to prioritize the most promising technologies required to achieve UEET program goals for the fuel-burn and NOx reductions.

Tong, Michael T.↗

Advanced Seal Sessions I and II

As aircraft operators continue to seek higher fuel efficiency, lower emissions, and longer on-wing performance, turbine engine designers are scrutinizing all components for areas of improvement. To achieve overall goals, turbine pressure ratios and by-pass ratios continue to climb. Also, designers are seeking to minimize parasitic and cooling flows to extract the most useful work out of the flow stream, placing a renewed interest on seal technology and secondary flow path management. In the area of future manned spacecraft, advancements are being examined for both habitat seals and re-entry thermal protection system thermal barrierseals. For long duration space craft, designers are continuing to look for savings in parasitic losses to reduce the amount of cabin re-supply air that needs to be brought along. This is placing greater demands on seal designs and materials to exhibit low leakage and be resistant to space environments. For future missions to and from distant planets, the re-entry heating will be higher than for low-earth orbit or lunar return motivating advanced thermal barrier development. This presentation will provide an overview of the seal challenges and opportunities in these diverse areas.

turbine engines↗

Correlating Time-Resolved Pressure Measurements With Rim Sealing Effectiveness for Real-Time Turbine Health Monitoring

Purge flow is bled from the upstream compressor and supplied to the under-platform region to prevent hot main gas path ingress that damages vulnerable under-platform hardware components. A majority of turbine rim seal research has sought to identify methods of improving sealing technologies and understanding the physical mechanisms that drive ingress. While these studies directly support the design and analysis of advanced rim seal geometries and purge flow systems, the studies are limited in their applicability to real-time monitoring required for condition-based operation and maintenance. As operational hours increase for in-service engines, this lack of rim seal performance feedback results in progressive degradation of sealing effectiveness, thereby leading to reduced hardware life. To address this need for rim seal performance monitoring, this study utilizes measurements from a one-stage turbine research facility operating with true-scale engine hardware at engine-relevant conditions. Time-resolved pressure measurements collected from the rim seal region are regressed with sealing effectiveness through the use of common machine learning techniques to provide real-time feedback of sealing effectiveness. Two modeling approaches are presented that use a single sensor to predict sealing effectiveness accurately over a range of two turbine operating conditions. Here, the results show that an initial purely data-driven model can be further improved using domain knowledge of relevant turbine operations, which yields sealing effectiveness predictions within 3% of measured values.

42 ENGINEERING↗

Correlating Time-Resolved Pressure Measurements With Rim Sealing Effectiveness for Real-Time Turbine Health Monitoring

Purge flow is bled from the upstream compressor and supplied to the under-platform region to prevent hot main gas path ingress that damages vulnerable under-platform hardware components. A majority of turbine rim seal research has sought to identify methods of improving sealing technologies and understanding the physical mechanisms that drive ingress. While these studies directly support the design and analysis of advanced rim seal geometries and purge flow systems, the studies are limited in their applicability to real-time monitoring required for condition-based operation and maintenance. As operational hours increase for in-service engines, this lack of rim seal performance feedback results in progressive degradation of sealing effectiveness, thereby leading to reduced hardware life. To address this need for rim seal performance monitoring, the present study utilizes measurements from a one-stage turbine research facility operating with true-scale engine hardware at engine-relevant conditions. Time-resolved pressure measurements collected from the rim seal region are regressed with sealing effectiveness through the use of common machine learning techniques to provide real-time feedback of sealing effectiveness. Two modelling approaches are presented that use a single sensor to predict sealing effectiveness accurately over a range of two turbine operating conditions. Results show that an initial purely data-driven model can be further improved using domain knowledge of relevant turbine operations, which yields sealing effectiveness predictions within three percent of measured values.

Compressors↗

Brush Seal Arrangement for the RS-68 Turbopump Set

The nature of the RS-68 turbopumps requires that the hydrogen seals separating the pump from the turbine must have extremely low levels of leakage and be contained in small packages. Conventional seal technologies are not able to reasonably satisfy such design requirements. A review of experimental measurements and analysis publications suggests that brush seals are well suited for the design requirements. Brush seals are shown to have less leakage than conventional labyrinth and damper seals and have no adverse effects on the rotordynamics of the machine. The bulk-flow analysis presented by Hendricks et al. is used as a guideline to create a spreadsheet that provides mass flow through the seal and heat generated by the rubbing contact of the bristles on the shaft. The analysis is anchored to published data for LN2 and LH2 leakage tests. Finally, the analysis is used to design seals for both applications. It is observed that the most important analysis parameter is the thickness of the bristle pack and its relationship to seal clearance, lay angle and pressure drop.

Nunez, D.↗

Design considerations in mechanical face seals for improved performance. 2: Lubrication

The importance of sealing technology in our industrial, chemical-oriented society in regard to maintenance and environmental contamination is pointed out. It is stated that seal performance (leakage, life) is directly related to seal lubrication. Current thinking in regard to seal lubrication is reviewed; the effect of energy dissipation in the thin lubricating film separating the sealing faces is pointed out, and the results of vaporization due to heating are illustrated. Also, hydrodynamic lubrication is reviewed, and an inherent tendency for the seal to operate with angular misalignment is shown. Recent work on hydrostatic effects is summarized and the conditions for seal instability are discussed. Four different modes of seal lubrication are postulated with the mode type being a strong function of speed and pressure.

Ludwig, L. P.↗

Design considerations in mechanical face seals for improved performance. II - Lubrication

The importance of sealing technology in the U.S. industrial chemical-orientated society in regard to maintenance and environmental contamination is pointed out. It is stated that seal performance (leakage, life) is directly related to seal lubrication, which is a mechanism not well understood. Current thinking in regard to seal lubrication is reviewed, the effect of energy dissipation in the thin lubricating film separating the sealing faces is pointed out, and the results of vaporization due to heating are illustrated. Also, hydrodynamic lubrication is reviewed, and an inherent tendency for the seal to operate with angular misalignment is pointed out. Recent work on hydrostatic effects is summarized and the conditions for seal instability are discussed. Four different modes of seal lubrication are postulated with the mode type being a strong function of speed and pressure.

Ludwig, L. P.↗

Advanced Control Surface Seal Development at NASA GRC for 3rd Generation RLV

NASA's Glenn Research Center (GRC) is developing advanced control surface seal technologies for the 3rd Generation RLV program. GRC has designed several new test rigs to simulate the temperatures, pressures, and scrubbing conditions that seals would have to endure during service. A hot compression test rig and hot scrub test rig are being developed to perform tests at temperatures up to 3000 F. Another new test rig allows simultaneous seal flow and scrub tests at room temperature to evaluate changes in seal performance with scrubbing. High temperature ceramic preloading devices are being developed and evaluated as ways to improve seal resiliency.

Dunlap, Patrick H., Jr.↗

Fire- and Water-Resistant Prefilter

The goal of this project was to modify existing LLNL ceramic HEPA filter technology to create ceramic prefilters, which could first be implemented in nuclear facilities or hospitals and universities. The objectives were as follows: 1) Demonstrate sealing technology capable of withstand ≥ 400°C, 2) Design and fabricate a ceramic prefilter unit for flow rates ≥ 50 cfm, 3) Test prefilter prototype filtration efficiency and pressure drop before and after a relevant thermal exposure. Concurrently to prototype creation was a preliminary effort to develop a custom nuclear prefilter sealant, improving upon what is commercially available. An advantage to using prefilters that are not credited for HEPA filtration, but to protect HEPA filters in nuclear ventilation systems, is that absolute qualified performance to HEPA standards (e.g. pressure drop, filtration efficiency) is not required. This prefilter prototype aligns our technology with the more viable, lower risk market entry point which can be used to establish costs, performance and manufacturing principles necessary to overcome the primary market barrier.

36 MATERIALS SCIENCE↗

A Mechanistic-Based Healing Model for Self-Healing Glass Seals Used in Solid Oxide Fuel Cells

The usage of self-healing glass as hermetic seals is a recent advancement in sealing technology development for the planar solid oxide fuel cells (SOFCs). Because of its capability of restoring the mechanical properties at elevated temperatures, the self-healing glass seal is expected to provide high reliability in maintaining the long-term structural integrity and functionality of SOFCs. In order to accommodate the design and to evaluate the effectiveness of such engineering seals under various thermo-mechanical operating conditions, computational modeling framework needs to be developed to accurately capture and predict the healing behavior of the glass material. In the present work, a mechanistic-based two-stage model was developed to study the stress and temperature-dependent crack healing of the self-healing glass materials. The model was first calibrated by experimental measurements combined with the kinetic Monte Carlo (kMC) simulation results and then implemented into the finite element analysis (FEA). The effects of various factors, i.e. stress, temperature, crack morphology, on the healing behavior of the glass were investigated and discussed.

30 DIRECT ENERGY CONVERSION↗

Pressure Actuated Leaf Seals for Improved Turbine Shaft Sealing

This presentation introduces a shaft seal in which leaf seal elements are constructed from slotted shim material formed and layered into a frusto-conical assembly. Limited elastic deflection of seal leaves with increasing system pressure close large startup clearance to a small, non-contacting, steady state running clearance. At shutdown seal elements resiliently retract as differential seal pressure diminishes. Large seal clearance during startup and shutdown provides a mechanism for rub avoidance. Minimum operating clearance improves performance and non-contacting operation promises long seal life. Design features of this seal, sample calculations at differential pressures up to 2400 psid and benefit comparison with brush and labyrinth seals is documented in paper, AIAA 2005 3985, presented at the Advanced Seal Technology session of the Joint Propulsion Conference in Tucson this past July. In this presentation use of bimetallic leaf material will be discussed. Frictional heating of bimetallic leaf seals during a seal rub can relieve the rub condition to some extent with a change in seal shape. Improved leaf seal rub tolerance is expected with bimetallic material.

Grondahl, Clayton↗

New Air- and Water-Resistive Barriers -– Technology Verification

Infiltration and exfiltration are among the largest envelope-related contributors to the heating, ventilation, and air conditioning (HVAC) loads in commercial buildings. Air leakage is responsible for about 6% of the total energy used by the commercial building sector. New air sealing technologies have recently emerged that aim to improve the performance of air barrier systems by simplifying their installation procedure. These include the 3M 3015 primer-less self-adhered membrane, 3M 3015VP vapor permeable primer-less self-adhered membrane, and 3M 2085VP vapor permeable fluid-applied air barrier membrane. ORNL verified the performance of the 3M 3015, 3015VP and 2085VP air- and water- resistive barriers by conducting two field studies. The first one involved side-by-side evaluations in eight unoccupied test facilities in Cottage Grove, MN, that included the 3M membranes and commonly used air barrier materials such as a self-adhered membrane with primer and a mechanically-fastened membrane with taped joints. The facilities were monitored for 24 months and the collected data were used to calibrate simulation models that in turn were employed to calculate energy consumption and savings because of improvements in airtightness. After two years, results indicate that the test facilities with the new 3M technologies had leakage rates that were slightly lower than the buildings with traditional air barrier materials. The calibrated model for the test facility with the 3M 3015 membrane was used to calculate energy savings due to improved airtightness when compared to a building without an air barrier. Findings suggest that a building in Minneapolis, MN, or Fairbanks, AK, that has a properly installed air barrier system can have annual HVAC electricity use that is about 36% lower than if the building did not have an air barrier. Similarly, decreases in natural gas use can be about 25%. The second field evaluation involved the LifeSource building in Minneapolis, MN, and the Sierra Trading Post building in Woodbury, MN. Both of these were recently completed and use the 3M 3015 and 3015VP membranes as their air- and water- resistive barriers, respectively. Blower door test results show that LifeSource has an average air leakage rate of 0.06 cfm/ft 2 at 75 Pa, or 85% lower than the 0.4 cfm/ft 2 at 75 Pa specified in the 2015 International Energy Conservation Code (IECC). The leakage rate in the Sierra building is 0.15 cfm/ft 2 at 75 Pa or 63% than the IECC value. According to simulation results, LifeSource lowered its annual heating and cooling cost by about $\$$4600 or 10% when compared to a similar building that lacked an air barrier system. In the case of the Sierra building, savings were $5,900 or 41%. These field evaluations serve as examples of the level of building envelope airtightness that can be achieved by using air barrier materials that are properly installed, and illustrate the energy and financial savings that building envelopes with low air leakage rates could attain.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Westinghouse programs in pulsed homopolar power supplies

This document details Westinghouse's ongoing study of homopolar machines since 1929 with the major effort occurring in the early 1970's to the present. The effort has enabled Westinghouse to develop expertise in the technology required for the design, fabrication and testing of such machines. This includes electrical design, electromagnetic analysis, current collection, mechanical design, advanced cooling, stress analysis, transient rotor performance, bearing analysis and seal technology. Westinghouse is using this capability to explore the use of homopolar machines as pulsed power supplies for future systems in both military and commercial applications.

Litz, D. C.↗