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Pressure losses reduced without degrading combustion stability. Injection Posts form forest in cavity between oxygen manifold and secondary faceplate. Cavity is fuel manifold; fuel floods post forest and enters each post through side holes in shroud. Injector designed for improved assembly and maintenance. Posts accessible from primary combustion chamber side and changed for flow adjustment.
The low pressure turbine for the energy efficient engine is a five-stage configuration with moderate aerodynamic loading incorporating advanced features of decambered airfoils and extended blade overlaps at platforms and shrouds. Mechanical integrity of 18,000 hours on flowpath components and 36,000 hours on all other components is achieved along with no aeromechanical instabilities within the steady-state operating range. Selection of a large number (156) of stage 4 blades, together with an increased stage 4 vane-to-blade gap, assists in achieving FAR 36 acoustic goals. Active clearance control (ACC) of gaps at blade tips and interstage seals is achieved by fan air cooling judiciously applied at responsive locations on the casing. This ACC system is a major improvement in preventing deterioration of the 0.0381 cm (0.015 in.) clearances required to meet the integrated-core/low-spool turbine efficiency goal of 91.1% and the light propulsion system efficiency goal of 91.7%.
The results of the endurance and performance engine tests conducted on monocrystal/abrasive-tipped CF6-50 Stage 1 HPT blades fabricated in Task VII of MATE Project 3 are presented. Two engine tests are conducted. The endurance engine test is conducted for 1000 C cycles. The performance engine test is conducted on a variable cycle core engine. Posttest evaluation and analyses of the blades and shrouds included visual, dimensional, and destructive evaluations.
The development of a linear model for the prediction of labyrinth seal forces and on its comparison to available stiffness data is presented. A discussion of the relevance of fluid damping forces and the preliminary stages of a program to obtain data on these forces are examined. Fluid-dynamic forces arising from nonuniform pressure patterns in labyrinth seal glands are known to be potentially destablizing in high power turbomachinery. A well documented case in point is that of the space Shuttle Main Engine turbopumps. Seal forces are also an important factor for the stability of shrouded turbines, acting in that case in conjunction with the effects of blade-tip clearance variations.
The occurrence of a crack in the HPFTP first stage impeller of pump 2608 R2 during test 750-245 prompted this analysis to examine possible causes of the failure. Preliminary analysis, using an existing NASTRAN model of the impeller, showed a deficiency in the model's ability to reliably calculate stress in the area of concern (outboard edge of the impeller shroud). A new NASTRAN model was constructed to better define the stress state in the area of crack initiations. Static stress analysis and normal models analysis were performed on the new model. Results are presented.
The numerical simulation of turbine flows serves to enhance the understanding of the flow phenomena within multistage turbomachinery components. The direct benefit of this activity is improved modeling capability, which can be used to improve component efficiency and durability. A hierarchy of equations was formulated to assess the difficulty in analyzing the flow field within multistage turbomachinery components. The Navier-Stokes equations provides the most complete description. The simplest description is given by a set of equations that govern the quasi-one-dimensional flow. The number of unknowns to be solved for increases monotonically above the number of equations. The development of the additional set of equations needed to mathematically close the system of equations forms the closure problem associated with that level of description. For the Navier-Stokes equation there is no closure problem. For the quasi-one-dimensional equation set random flow fluctuations, unsteady fluctuations, nonaxisymmetric flow variations, and hub-to-shroud variations on the quasi-one-dimensional flow must be accounted for.
Several flow phenomena including flowfield periodicity, rotor shock oscillation, and rotor shock system geometry were investigated in a transonic low aspect ratio fan rotor using laser anemometry. Flow periodicity is found to increase with increasing rotor pressure rise, and to correlate with blade geometry variations. Analysis of time-accurate laser anemometer data indicates that the rotor shock oscillates about its mean location with an amplitude of 3 to 4 percent of rotor chord. The shock surface is nearly two-dimensional for levels of rotor pressure rise at and above the peak efficiency level but becomes more complex for lower levels of pressure rise. Spanwise shock lean generates radial flows due to streamline deflection in the hub-to-shroud streamsurface.
External heat-transfer rates were measured on a flat plate in the junction region of a circular cylinder mounted normal to the plate at a location 90 deg from the stagnation point. This configuration simulates the junction of the shroud with gas-turbine vanes. Heat-transfer results are presented for laminar, transition, and turbulent boundary layers for a Mach number of 0.14 with gas temperatures of approximately 750 deg R over a flat plate at room temperature. The measurements were made in air for a unit Reynolds number, Re/cm, range of 11,000 to 58,000. Heat-transfer measurements were conducted in the 70-ft long, 4-in. diameter shock tube. A shock-wave reflection technique was used to produce a flow Mach number of 0.14. Thin-film platinum heat gages were mounted on the flat plate and along the line of the stagnation point of the cylinder to measure the local heat flux in the junction region. The experimental heat-transfer data were correlated with the laminar and turbulent boundary-layer theories for the flat plate. With the cylinder the heat fluxes on the flat plate were greatly increased in the junction region compared to the heat flux for the plate alone.
The effective design of three-dimensional flow systems such as a clustered multinozzle shrouded exhaust system requires detailed analysis of the internal flowfield. It is pointed out that new numerical techniques on the most modern vector computers are making these analyses practicable. In this paper, the upwind differenced implicit conservative supracharacteristics method (CSCM) for three-dimensional viscous flow is presented. The new method is an implicit 'method of planes' symmetric Gauss-Seidel relaxation scheme. The data is conveniently stored on successive planes along the streamwise coordinate, and the system of equations is solved twice in each successive plane of the streamwise coordinate. The developed new three-dimensional compressible Navier-Stokes algorithm combines the best features of the storage and computationally efficient space marching procedures with the generality of time dependent techniques to solve flows with elliptic and streamwise separated flows.
This paper presents the results of a combined analytical and experimental investigation of low specific speed pumps for potential use as components of propellant feed systems for low thrust rocket engines. Shrouded impellers and open face impellers were tested in volute type and vaned diffuser type pumps. Full- and partial-emission diffusers and full- and partial-admission impellers were tested. Axial and radial loads, head and efficiency versus flow, and cavitation tests were conducted. Predicted performance of two pumps are compared when pumping water and liquid hydrogen. Detailed pressure loss and parasitic power values are presented for two pump configurations. Partial-emission diffusers were found to permit use of larger impeller and diffuser passages with a minimal performance penalty. Normal manufacturing tolerances were found to result in substantial power requirement variation with only a small pressure rise change. Impeller wear ring leakage was found to reduce pump pressure rise to an increasing degree as the pump flowrate was decreased.
Apparatus and method for pulling optical glass fibers in a containerless environment is disclosed which includes a single axis acoustical levitation furnace in which a specimen is levitated and melted. A reflector unit is carried in the interior of the furnace and includes a reflector disposed centrally about the acoustical axis of the levitator. The reflector unit includes a circular shroud of insulation and a copper sleeve inserted in the unit which is hollow at for receiving a cooling medium. A fiber pulling bore is formed centrally in the reflector unit surrounded by cooling jacket to enhance solidification and formation of a fiber. A starting fiber strand is introduced into the melt and pulled outwardly through bore whereby the specimen fiber is started and formed as pulled therethrough. In order to replenish the melt and thus enable a continous process, a movable secondary reflector is provided which captures a supplemental specimen pellet and by movement of the reflector transfers it to the melt.
A variable area radial turbine with a moveable nozzle sidewall was experimentally evaluated. The turbine was designed for an advanced variable capacity gas turbine rotorcraft engine. The turbine has a mass flow rate of 2.27 kg/sec (5.0 lbs/sec), and a rotor inlet temperature of 1477K (2200 F). Testing was conducted at a reduced inlet temperature, but the aerodynamic parameters and Reynolds numbers were duplicated. Overall performance was obtained for a range of nozzle areas from 50% to 100% of the maximum area. The test program determined the effect on performance of: (1) Moving the hub or shroud sidewall; (2) Sidewall-vane clearance leakage; (3) Vaneless space geometry change; and (4) Nozzle cooling flows. Data were obtained for a range of pressure ratios and speeds and are presented in a number of performance maps.
A rotor radial rub typically occurs in seals or at a blade tip or shroud when there is insufficient clearance, high vibration, or the shaft equilibrium position has been displaced to effectively limit the clearance (eccentricity). There are two extreme cases of radial rubs: full annular rub, when the rotor maintains continuous contact with the seal, etc.; and a partial rub, when the contact occurs during a fraction of the precession period. They both involve similar physical phenomena such as friction and modification of stiffness. In partial rubs with consecutive impacts, a significant average value of radial force is generated. This results in shaft average displacement in the direction opposite the rub location. The rotor rig demonstrates the characteristics of a partial lateral rub of varying severity and location. These characteristics include: (1) subharmonic components as a function of rotative speed/first balance resonance ratio and radial force; (2) higher harmonic content as a function of severity; (3) increased average rotor stiffness resulting in increased first balance resonance speed; and (4) change in overall orbital pattern as a sum of the unbalance response (1x) and subharmonic response (1nx).
Six small, low specific speed centrifugal pump configurations were designed, fabricated, and tested. The configurations included shrouded, and 25 and 100% admission open face impellers with 2 inch tip diameters; 25, 50, and 100% emission vaned diffusers; and volutes with conical exits. Impeller tip widths varied from 0.030 inch to 0.052 inch. Design specific speeds (N sub s = RPM*GPM**0.5.FT**0.75) were 430 (four configurations) and 215 (two configurations). The six configurations were tested with water as the pumped fluid. Noncavitating performance results are presented for the design speed of 24,500 rpm over a flowrate range from 1 to 6 gpm for the N sub s = 430 configurations and test speeds up to 29,000 rpm over a flowrate range from 0.3 to 1.2 gpm for the N sub s = 215 configurations. Cavitating performance results are presented over a flowrate range from 60 to 120% of design flow. Fabrication of the small pump conponents is also discussed.
The AGT101 ceramic gas turbine engine feasibility study has made use of the slip casting of silicon or silicon nitride powders to produce either reaction-bonded or sintered components such as turbine rotors, turbine shrouds, and inner and outer diffusers. Attention is given to the effects of processing parameters on the microstructure and properties of the finished components; the parameters encompass powder particle size distribution, casting slip viscosity, pH, and solid content fraction. The green slip cast components were consolidated by nitriding, sintering, or sinter/HIPping.
The aeroelastic stability of titanium and composite blades of low aspect ratio is examined over a range of design parameters, using a Rayleigh-Ritz formulation. The blade modes include a plate-type mode to account for chordwise bending. Chordwise flexibility is found to have a significant effect on the unstalled supersonic flutter of low aspect ratio blades, and also on the stability of tip sections of shrouded fan blades. For blades with a thickness of less than approximately four percent of chord, the chordwise, second bending, and first torsion branches are all unstable at moderately high supersonic Mach numbers. For composite blades, the important structural coupling between bending and torsion cannot be modeled properly unless chordwise bending is accounted for. Typically, aft fiber sweep produces beneficial bending-torsion coupling that is stabilizing, whereas forward fiber sweep has the opposite effect. By using crossed-ply laminate configurations, critical aeroelastic modes can be stabilized.
Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and analytical studies comprised AGT 100 activities during the 1985 year. Ten experimental assemblies (builds) were evaluated using two engines. Accrued operating time was 120 hr of burning and 170 hr total, bringing cumulative total operating time to 395 hr, all devoid of major failures. Tests identified the generator seals as the primary working fluid leakage sources. Power transfer clutch operation was demonstrated. An alpha SiC gasifier rotor engine test resulted in blade tip failures. Recurring case vibration and shaft whip have limited gasifier shaft speeds to 84%. Ceramic components successfully engine tested now include the SiC scroll assembly, Si3N3 turbine rotor, combustor assembly, regenerator disk bulkhead, turbine vanes, piston rings, and couplings. A compressor shroud design change to reduce heat recirculation back to the inlet was executed. Ceramic components activity continues to focus on the development of state-of-the-art material strength characteristics in full-scale engine hardware. Fiber reinforced glass-ceramic composite turbine (inner) backplates were fabricated by Corning Glass Works. The BMAS/III material performed well in engine testing. Backplates of MAS material have not been engine tested.
Measurements of the unsteady velocity field within the stator row of a transonic axial-flow fan were acquired using a laser anemometer. Measurements were obtained on axisymmetric surfaces located at 10 and 50 percent span from the shroud, with the fan operating at maximum efficiency at design speed. The ensemble-average and variance of the measured velocities are used to identify rotor-wake-generated (deterministic) unsteadiness and turbulence, respectively. Correlations of both deterministic and turbulent velocity fluctuations provide information on the characteristics of unsteady interactions within the stator row. These correlations are derived from the Navier-Stokes equation in a manner similar to deriving the Reynolds stress terms, whereby various averaging operators are used to average the aperiodic, deterministic, and turbulent velocity fluctuations which are known to be present in multistage turbomachines. The correlations of deterministic and turbulent velocity fluctuations throughout the axial fan stator row are presented. In particular, amplification and attenuation of both types of unsteadiness are shown to occur within the stator blade passage.