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At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Novel Engineering and Fabrication Techniques Tested in Low-Noise- Research Fan Blades

A major source of fan noise in commercial turbofan engines is the interaction of the wake from the fan blades with the stationary vanes (stators) directly behind them. The Trailing Edge Blowing (TEB) project team at the NASA Glenn Research Center designed and fabricated new fan blades to study the effects of fan trailing edge blowing as a potential noise-reduction concept. The intent is to fill the rotor wake by supplying air to the rotor blade trailing edge at the proper conditions to minimize the wake deficit, and thus generate less noise. The TEB hardware is designed for the Active Noise Control Fan (ANCF) test rig in Glenn's Aeroacoustic Propulsion Laboratory. For this test, the air is fed from an external supply through the shaft of the rig. It is distributed to the base of each blade through an impeller, where it is forced into a plenum at the core of each blade. In actual engine configuration, air would most likely be bled from the compressor, but only at times when noise is an issue, such as takeoffs and landings. Glenn researchers designed and manufactured the blades in-house, using new techniques and concepts. The skins, which were designed for maximum strength in the directions of highest stress, were molded from multiple layers of carbon fiber. Considerable use was made of rapid prototyping techniques, such as laser sintering. The core was sintered from a lightweight polymer, and the retainer was CNC-machined (computer numerical control machined) from aluminum. All the components were joined with a cold-cure aerospace adhesive. These techniques and processes reduced the overall cost and allowed the new concept to be studied much sooner than would be possible using traditional fabrication methods. Since this test rig did not support the use of blade-monitoring techniques such as strain gauges, extensive bench testing was required to qualify the design. The blades were examined using a variety of methods including holography, pull tests (cyclic and failure), shake tests, rap tests, and nondestructive inspection. Acoustic testing of the ANCF fan using TEB has been ongoing since January of 2001. The fan has completed about 100 hr of testing with no structural, vibrational, or fatigue problems. Far-field acoustic measurements, in-duct mode measurements, precise hot wire surveys, and detailed performance measurements are providing data for evaluating the concept. The far-field noise data show that tone noise was reduced significantly with the initial ANCF TEB fan design. In addition, a significant reduction in unsteady stator loading has been measured, indicating the potential for stator broadband noise reduction. The acoustic benefits will be assessed and important design parameters identified to improve the ability to fully exploit any benefit provided by this technique. On the basis of the success of trailing edge blowing, Glenn plans to continue this research with a higher speed, higher pressure ratio fan operating in an acoustic wind tunnel to simulate flight conditions.

Cunningham, Cameron C.↗
NASA NTRS1990

Aerodynamic characteristics of two rotorcraft airfoils designed for application to the inboard region of a main rotor blade

A wind tunnel investigation was conducted to determine the 2-D aerodynamic characteristics of two new rotorcraft airfoils designed especially for application to the inboard region of a helicopter main rotor blade. The two new airfoils, the RC(4)-10 and RC(5)-10, and a baseline airfoil, the VR-7, were all studied in the Langley Transonic Tunnel at Mach nos. from about 0.34 to 0.84 and at Reynolds nos. from about 4.7 to 9.3 x 10 (exp 6). The VR-7 airfoil had a trailing edge tab which is deflected upwards 4.6 degs. In addition, the RC(4)-10 airfoil was studied in the Langley Low Turbulence Pressure Tunnel at Mach nos. from 0.10 to 0.44 and at Reynolds nos. from 1.4 to 5.4 x 10 (exp 6) respectively. Some comparisons were made of the experimental data for the new airfoils and the predictions of two different theories. The results of this study indicates that both of the new airfoils offer advantages over the baseline airfoil. These advantages are discussed.

Noonan, Kevin W.↗
NASA NTRS1993

Simplified Computation Of Blade-Surface Coordinates

Coordinates of points on complicated three-dimensional surface of turbo-machine blade computed by method partly simplifying three-dimensional problem to two-dimensional problem. Method implemented in computer program enabling rapid hydrodynamical evaluation and optimization of blade surface prior to definition of final design of, and analysis of stresses in blade. By incorporating program into procedure for designing turbomachine, one reduces time spent on design iterations.

Chen, Wei-Chung↗
NASA NTRS2019

Design and Analysis of a Tool for Automated Fiber Placement of Composite Wind Tunnel Blades

For decades, composite wind tunnel blades have been constructed using labor-intensive hand layup processes. Automated Fiber Placement (AFP) is a relatively new technology that has not seen widespread use in manufacturing composite wind tunnel blades. AFP offers the potential for reduced manufacturing time, reduced cost, and improved consistency compared to traditional hand layup procedures. These manufacturing qualities are becoming increasingly important as existing wind tunnel blades are replaced due to impact damage or wear and tear from decades of use. Researchers at the NASA Langley Research Center are currently using the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to investigate the feasibility of AFP for manufacturing composite wind tunnel blades. ISAAC uses manufacturing tools as surfaces on which to place fiber tows. A manufacturing tool was developed for using AFP to build a wind tunnel blade shape. This paper presents the structural design and analysis of this tool, for use with AFP, constructed from high temperature thermoplastics. The tool fabricated by this design process was successfully used for AFP and oven cure of two representative airfoil shaped composite structures.

Brian Mason↗
NASA NTRS2013

The Aerodynamic Performance of an Over-the-Rotor Liner With Circumferential Grooves on a High Bypass Ratio Turbofan Rotor

While liners have been utilized throughout turbofan ducts to attenuate fan noise, additional attenuation is obtainable by placing an acoustic liner over-the-rotor. Previous experiments have shown significant fan performance losses when acoustic liners are installed over-the-rotor. The fan blades induce an oscillating flow in the acoustic liners which results in a performance loss near the blade tip. An over-the-rotor liner was designed with circumferential grooves between the fan blade tips and the acoustic liner to reduce the oscillating flow in the acoustic liner. An experiment was conducted in the W-8 Single-Stage Axial Compressor Facility at NASA Glenn Research Center on a 1.5 pressure ratio fan to evaluate the impact of this over-the-rotor treatment design on fan aerodynamic performance. The addition of a circumferentially grooved over-the-rotor design between the fan blades and the acoustic liner reduced the performance loss, in terms of fan adiabatic efficiency, to less than 1 percent which is within the repeatability of this experiment.

Bozak, Richard F.↗
NASA NTRS2013

The Aerodynamic Performance of an Over-The-Rotor Liner with Circumferential Grooves on a High Bypass Ratio Turbofan Rotor

While liners have been utilized throughout turbofan ducts to attenuate fan noise, additional attenuation is obtainable by placing an acoustic liner over-the-rotor. Previous experiments have shown significant fan performance losses when acoustic liners are installed over-the-rotor. The fan blades induce an oscillating flow in the acoustic liners which results in a performance loss near the blade tip. An over-the-rotor liner was designed with circumferential grooves between the fan blade tips and the acoustic liner to reduce the oscillating flow in the acoustic liner. An experiment was conducted in the W-8 Single-Stage Axial Compressor Facility at NASA Glenn Research Center on a 1.5 pressure ratio fan to evaluate the impact of this over-the-rotor treatment design on fan aerodynamic performance. The addition of a circumferentially grooved over-the-rotor design between the fan blades and the acoustic liner reduced the performance loss, in terms of fan adiabatic efficiency, to less than 1% which is within the repeatability of this experiment.

Bozak, Rick↗
NASA NTRS2019

Assessment of Automated Fiber Placement for the Fabrication of Composite Wind Tunnel Blades

Composite wind tunnel blades are frequently fabricated by hand layup of prepreg fabrics. Though well proven, this fabrication method is laborious and expensive. The study described in this paper used the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at the NASA Langley Research Center to explore whether automated fiber placement (AFP) could reduce manufacturing time and cost for production of wind tunnel blades. Two blades, taken from two NASA wind tunnels, were investigated as representative geometries. Computer-aided design models of the blade surfaces were created, and AFP process planning and programming were employed to study the manufacturability of the shapes. A placement/cure tool was manufactured for the chosen blade surface from thermoplastic material using an additive manufacturing process. The present study revealed that the AFP head geometry, primarily the heater configuration of the ISAAC system, is the primary constraint that limits the ability to manufacture the selected wind tunnel fan blades using AFP.

Grenoble, Ray↗
DOE OSTI2026

Comparison of juvenile white sturgeon blade strike survival through a conventional and a novel hydropower turbine

Hydropower is a globally important renewable energy source with profound impacts on aquatic organisms, including direct injury and mortality to fish that move through hydropower facilities. While it is expected that the characteristics of turbine design and operation influence the type, frequency, and magnitude of injuries suffered by entrained fish, few direct comparisons exist to illustrate differences in fish survival outcomes for conventional and novel turbine designs. This study evaluated blade strike-associated injury and mortality rates for juvenile white sturgeon (Acipenser transmontanus) passed through a model-scale turbine equipped with a runner having conventional blade profiles (thin, straight leading edges) and the same turbine equipped with a runner designed for improved fish survival (thick, slanted leading edges). In both trials, head and turbine runner rotational speeds were matched to produce five blade peripheral speeds between 15.0 and 27.6 m/s. High-speed video was captured for all turbine passage events. Fish were assessed for injuries following passage, and mortalities were assessed immediately after passage and after 48 h. Conventional runner passage resulted in 42% to 78% survival after 48 h, with approximately one-third of all tested fish killed by severing. Under the same test conditions, immediate and 48 h survival rates through the novel runner were 100% except at the highest speed condition (95.6% survival at 48 h). These results clearly indicate that turbine design has a profound effect on fish survival, and suggest that thoughtful redesign of hydropower equipment could significantly ameliorate the risks of blade strike mortality.

13 HYDRO ENERGY↗
NASA NTRS2024

Tail-Cone Thruster Fan Rotor Flutter Analysis

The aeroelastic stability of a tail cone thruster fan was analyzed for three structural modes and various nodal diameter patterns. Computational fluid dynamics modeling with blade vibrations was used in the analyses performed at design (peak-efficiency) and two near-stall conditions at the design rotational speed. Aerodynamic damping was used to assess flutter since this integrally bladed rotor design will have minimal structural damping. Aerodynamic damping was found to be low at the design condition. For the first mode, aerodynamic damping was seen to decrease towards stall, vanishing for a zero nodal diameter pattern. Further decrease in mass flow led to negative aerodynamic damping (flutter) for the first and second nodal diameters in the near stall condition. The flowfield at this lowest mass flow rate exhibited some additional unsteadiness at higher frequency. The sensitivity of results to time step and amplitudes of vibration was examined and found to be very satisfactory. The largest uncertainty in the results comes from the observed sensitivity of the aerodynamic damping to details of the variation of grid deformations in the blade passage mesh from the blade passage to the boundaries. For the parametric variations analyzed, the calculated aerodynamic damping is lower if the grid deformations near the blade surface are higher. Further work is needed to understand the cause of this sensitivity and find possible solutions to reduce the effects on flutter predictions.

Fan↗
NASA NTRS2004

"Fan-Tip-Drive" High-Power-Density, Permanent Magnet Electric Motor and Test Rig Designed for a Nonpolluting Aircraft Propulsion Program

A scaled blade-tip-drive test rig was designed at the NASA Glenn Research Center. The rig is a scaled version of a direct-current brushless motor that would be located in the shroud of a thrust fan. This geometry is very attractive since the allowable speed of the armature is approximately the speed of the blade tips (Mach 1 or 1100 ft/s). The magnetic pressure generated in the motor acts over a large area and, thus, produces a large force or torque. This large force multiplied by the large velocity results in a high-power-density motor.

Brown, Gerald V.↗
NASA NTRS1993

CFD Parametric Study of Consortium Impeller

Current design of high performance turbopumps for rocket engines requires effective and robust analytical tools to provide design impact in a productive manner. The main goal of this study is to develop a robust and effective computational fluid dynamics (CFD) pump model for general turbopump design and analysis applications. A Finite Difference Navier-Stokes flow solver, FDNS, which includes the extended k-epsilon turbulence model and appropriate moving interface boundary conditions, was developed to analyze turbulent flows in turbomachinery devices. A second-order central difference scheme plus adaptive dissipation terms was employed in the FDNS code, along with a predictor plus multi-corrector pressure-based solution procedure. The multi-zone, multi-block capability allows the FDNS code to efficiently solve flow fields with complicated geometry. The FDNS code has been benchmarked by analyzing the pump consortium inducer, and it provided satisfactory results. In the present study, a CFD parametric study of the pump consortium impeller was conducted using the FDNS code. The pump consortium impeller, with partial blades, is a new design concept of the advanced rocket engines. The parametric study was to analyze the baseline design of the consortium impeller and its modification which utilizes TANDEM blades. In the present study, the TANDEM blade configuration of the consortium impeller considers cut full blades for about one quarter chord length from the leading edge and clocks the leading edge portion with an angle of 7.5 or 22.5 degrees. The purpose of the present study is to investigate the effect and trend of the TANDEM blade modification and provide the result as a design guideline. A 3-D flow analysis, with a 103 x 23 x 30 mesh grid system and with the inlet flow conditions measured by Rocketdyne, was performed for the baseline consortium impeller. The numerical result shows that the mass flow rate splits through various blade passages are relatively uniform. Due to the complexity of blade geometries, the TANDEM blade configurations were analyzed with the multi-zone grid structure. Both the 7.5 deg- and the 22.5 deg-clocking TANDEM blade cases utilized a 80K mesh system. The numerical result of two TANDEM blade modifications indicates the efficiency and the head are worse than those of the baseline case due to larger flow distortion. The gap between the TANDEM blade and the full blade allows the flow passes through and heavily loads the pressure side of the partial blade such that flow reversal occurs near the suction side of the splitter. The flow split at the exit of impeller blades is very non-uniform for TANDEM blade cases, and this will greatly induce the side load on the diffuser. Therefore, the TANDEM blade modification in the present CFD analysis does not improve the performance of the consortium impeller.

Cheng, Gary C.↗
NASA NTRS2023

Nasa Hytec CMC Turbine Blade Durability

The objective of the CMC turbine blade durability program is to identify critical material and design parameters that affect durability of ceramic matrix composite (CMC) turbine blades. A baseline architecture for a cooled high-pressure turbine (HPT) CMC blade and accompanying sub-component test articles were developed with the intent to demonstrate through analysis and subcomponent testing how material and design parameters impact key failure modes. As part of this program, a notional architecture for a cooled CMC blade was matured through a design review rhythm to produce a blade test article containing the necessary features required for operation in an engine like environment. Further validation of the durability of these features were achieved through coupon and sub-component testing to demonstrate the durability of cooling hole configurations and blade attachment designs. Analytical methods were also used to evaluate the acceptability of the baseline blade test article architecture against relevant design requirements and identify abatement and recommended changes to key design drivers to improve component durability for future design iterations.

CMC, Blade↗
DOE OSTI2023

Aero‐servo‐elastic co‐optimization of large wind turbine blades with distributed aerodynamic control devices

Abstract This work introduces automated wind turbine optimization techniques based on full aero‐servo‐elastic models and investigates the potential of trailing edge flaps to reduce the levelized cost of energy (LCOE) of wind turbines. The Wind Energy with Integrated Servo‐control (WEIS) framework is improved to conduct the presented research. Novel methods for the generic implementation and tuning of trailing edge flap devices and their controller are also introduced. Primary flap and controller parameters are optimized to demonstrate potential maximum blade tip deflection reductions of 21 % . Concurrent design optimization (i.e., co‐design) of a novel segmented wind turbine blade with trailing edge flaps and its controller is then conducted to demonstrate blade cost savings of 5 % . Additionally, rotor diameter co‐design optimization is demonstrated to reduce the LCOE by 1.3 % without significant load increases to the tower. These results demonstrate the efficacy of control co‐design optimization using trailing edge flaps, and the entirety of this work provides a foundation for numerous control co‐design‐oriented studies for distributed aerodynamic control devices.

17 WIND ENERGY↗