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At least 811 records · Page 45

A low-cost optical data acquisition system for vibration measurement

A low cost optical data acquisition system was designed to measure deflection of vibrating rotor blade tips. The basic principle of the new design is to record raw data, which is a set of blade arrival times, in memory and to perform all processing by software following a run. This approach yields a simple and inexpensive system with the least possible hardware. Functional elements of the system were breadboarded and operated satisfactorily during rotor simulations on the bench, and during a data collection run with a two-bladed rotor in the Lewis Research Center Spin Rig. Software was written to demonstrate the sorting and processing of data stored in the system control computer, after retrieval from the data acquisition system. The demonstration produced an accurate graphical display of deflection versus time.

Posta, S. J.↗

Multipoint Aerostructural Optimization of Wind Turbine Rotors Using a Coupled Blade‐Resolved Aerostructural Solver

Physics‐based design optimization workflows thread the needle between computational cost limitations and simulation complexity, often compromising between modeling detail and the range of operating design conditions. Multipoint aerostructural optimization of wind turbine rotors has so far been confined to low‐fidelity analyses or to high‐fidelity studies with simplified structural models, leaving the most complex design trade‐offs unexplored. We close this gap by performing the first tightly coupled gradient‐based multipoint aerostructural rotor optimization using 3D aerodynamic and structural solvers with discrete coupled adjoints. The optimizer simultaneously varies blade planform, airfoil shapes, and structural thickness through more than 270 design variables, minimizing a weighted combination of rotor mass and power across multiple wind speeds. Applied to a modified DTU 10‐MW benchmark under conservative structural and aerodynamic constraints, our multipoint optimization reduces rotor mass by up to 36% and increases power by 12%–15% across the main operating conditions; biasing the objective toward power yields power gains up to 18% and a 17% mass reduction. For a nominal wind distribution, 3‐point rotor designs accounting for low RPM and high thrust conditions capture dominant trade‐offs and outperform single‐point designs. Adding two off‐design points changes individual‐condition power by less than 3% but leaves the weighted average within 0.5%, and the mass‐power bias has a stronger effect on the final design than the operating‐point weighting itself. Our framework extends naturally to richer load cases and site‐specific wind distributions, providing a basis for high‐fidelity multipoint design earlier in industrial workflows.

17 WIND ENERGY↗

Structural tailoring of high-speed turbine blades (SSME/STAEBL)

Space shuttle main engine (SSME) blades are subject to severe thermal, pressure, and forced vibration environments. Structural optimization provides an automated alternative to time consuming iterations. Any number of analyses, design variables, and constraints can be incorporated in a structural optimization computer code. This idea was applied to develop the code SSME/STAEBL, which is a stand alone code suitable for automated design of SSME turbopump blades. Additions and modifications of STAEBL included in SSME/STAEBL include the following: (1) thermal stress analysis, (2) gas dynamic (pressure) loads, (3) temperature-dependent material and thermal properties, (4) forced vibrations, (5) tip displacement constraints, (6) single crystal material analysis, (7) blade cross-section stacking offsets, and (8) direct time integration algorithm for transient dynamic response.

Rubinstein, Robert↗

Helicopter far-field acoustic levels as a function of reduced main-rotor advancing blade-tip Mach number

During the design of a helicopter, the weight, engine, rotor speed, and rotor geometry are given significant attention when considering the specific operations for which the helicopter will be used. However, the noise radiated from the helicopter and its relationship to the design variables is currently not well modeled with only a limited set of full-scale field test data to study. In general, limited field data have shown that reduced main-rotor advancing blade-tip Mach numbers result in reduced far-field noise levels. The status of a recent helicopter noise research project is reviewed. It is designed to provide flight experimental data which may be used to further understand helicopter main-rotor advancing blade-tip Mach number effects on far-field acoustic levels. Preliminary results are presented relative to tests conducted with a Sikorsky S-76A helicopter operating with both the rotor speed and the flight speed as the control variable. The rotor speed was operated within the range of 107 to 90 percent NR at nominal forward speeds of 35, 100, and 155 knots.

Mueller, Arnold W.↗

Overall Cooling Effectiveness of Internally Cooled Additively Manufactured Blades

By utilizing additive manufacturing, novel internal cooling designs can be quickly and cheaply vetted to enhance blade cooling performance. This improvement allows for higher turbine inlet temperatures while reducing the amount of coolant needed, therefore increasing the overall efficiency of small industrial gas turbines.

additive manufacturing↗

Tuned-Mass Damper For Turbine Blades

Resonances altered to suppress vibrations. Damping ring designed to suppress fundamental-bending-mode vibrations of blades on integrally bladed turbine rotor. Damping ring and turbine blades behave analogously to two-mass, two-spring system.

Marra, John J.↗

Active Blade Vibration Control Being Developed and Tested

Gas turbine engines are currently being designed to have increased performance, lower weight and manufacturing costs, and higher reliability. Consequently, turbomachinery components, such as turbine and compressor blades, have designs that are susceptible to new vibration problems and eventual in-service failure due to high-cycle fatigue. To address this problem, researchers at the NASA Glenn Research Center are developing and testing innovative active blade vibration control concepts. Preliminary results of using an active blade vibration control system, involving a rotor supported by an active magnetic bearing in Glenn's Dynamic Spin Rig, indicate promising results (see the photograph). Active blade vibration control was achieved using feedback of blade strain gauge signals within the magnetic bearing control loop. The vibration amplitude was reduced substantially (see the graphs). Also, vibration amplitude amplification was demonstrated; this could be used to enhance structural mode identification, if desired. These results were for a nonrotating two-bladed disk. Tests for rotating blades are planned. Current and future active blade vibration control research is planned to use a fully magnetically suspended rotor and smart materials. For the fully magnetically suspended rotor work, three magnetic bearings (two radial and one axial) will be used as actuators instead of one magnetic bearing. This will allow additional degrees of freedom to be used for control. For the smart materials work, control effectors located on and off the blade will be considered. Piezoelectric materials will be considered for on-the-blade actuation, and actuator placement on a stator vane, or other nearby structure, will be investigated for off-the-blade actuation. Initial work will focus on determining the feasibility of these methods by performing basic analysis and simple experiments involving feedback control.

Johnson, Dexter↗

The Effect of Variable Chord Length on Transonic Axial Rotor Performance

Aircraft fan and compressor blade leading edges suffer from atmospheric particulate erosion that reduces aerodynamic performance. Recontouring the blade leading edge region can restore blade performance. This process typically results in blades of varying chord length. The question therefore arises as to whether performance of refurbished fans and compressors could be further improved if blades of varying chord length are installed into the disk in a certain order. To investigate this issue the aerodynamic performance of a transonic compressor rotor operating with blades of varying chord length was measured in back-to-back compressor test rig entries. One half of the rotor blades were the full nominal chord length while the remaining half of the blades were cut back at the leading edge to 95% of chord length and recontoured. The rotor aerodynamic performance was measured at 100, 80, and 60% of design speed for three blade installation configurations: nominal-chord blades in half of the disk and short-chord blades in half of the disk; four alternating quadrants of nominal-chord and short-chord blades; nominal-chord and short-chord blades alternating around the disk. No significant difference in performance was found between configurations, indicating that blade chord variation is not important to aerodynamic performance above the stall chord limit if leading edges have the same shape. The stall chord limit for most civil aviation turbofan engines is between 94-96% of nominal (new) blade chord.

Roberts, William B.↗

Overview of Current Turbine Aerodynamic Analysis and Testing at MSFC

An overview of the current turbine aerodynamic analysis and testing activities at NASA/Marshall Space Flight Center (MSFC) is presented. The presentation is divided into three areas. The first area is the three-dimensional (3D), unsteady Computational Fluid Dynamics (CFD) analysis of the Fastrac turbine. Results from a coupled nozzle, blade, and exit guide vane analysis and from an uncoupled nozzle and coupled blade and exit guide vane will be presented. Unsteady pressure distributions, frequencies, and exit profiles from each analysis will be compared and contrasted. The second area is the testing and analysis of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) turbine with instrumented first stage blades. The SSME HPFTP turbine was tested in air at the MSFC Turbine Test Equipment (TTE). Pressure transducers were mounted on the first stage blades. Unsteady, 3D CFD analysis was performed for this geometry and flow conditions. A sampling of the results will be shown. The third area is a status of the Turbine Performance Optimization task. The objective of this task is to improve the efficiency of a turbine for potential use on a next generation launch vehicle. This task includes global optimization for the preliminary design, detailed optimization for blade shapes and spacing, and application of advanced CFD analysis. The final design will be tested in the MSFC TTE.

Griffin, Lisa W.↗

STAEBL/general composites with hygrothermal effects (STAEBL/GENCOM)

A computer code has been developed to perform structural optimization of turbine blades made from angle ply fiber composite laminates. Design variables available for optimization include geometric parameters such as blade thickness distribution and root chord, and composite material parameters such as ply angles and numbers of plies of each constituent material. Design constraints include resonance margins, forced response margins, maximum stress, and maximum ply combined stress. A general description of this code is given. Design optimization studies for typical blades are presented.

Rubenstein, Robert↗

STAEBL/General composites with hygrothermal effects (STAEBL/GENCOM)

A computer code has been developed to perform structural optimization of turbine blades made from angle ply fiber composite laminates. Design variables available for optimization include geometric parameters such as blade thickness disribution and root chord, and composite material parameters such as ply angles and numbers of plies of each constituent material. Design constraints include resonance margins, forced response margins, maximum stress, and maximum ply combined stress. A general description of this code is given. Design optimization studies for typical blades are presented.

Rubinstein, R.↗

Alloy Design Challenge: Development of Low Density Superalloys for Turbine Blade Applications

New low density single crystal (LDS) alloys have been developed for turbine blade applications, which have the potential for significant improvements in the thrust to weight ratio over current production alloys. An innovative alloying strategy was identified to achieve high temperature creep resistance, alloy density reductions, microstructural stability, and cyclic oxidation resistance. The approach relies on the use of molybdenum (Mo) as a potent solid solution strengthener for the nickel (Ni)-base superalloy; Mo has a density much closer to Ni than other refractory elements, such as rhenium (Re) or tungsten (W). A host of testing and microstructural examinations was conducted on the superalloy single crystals, including creep rupture testing, microstructural stability, cyclic oxidation, and hot corrosion. The paper will provide an overview of the single crystal properties that were generated in this new superalloy design space. The paper will also demonstrate the feasibility of this innovative approach of low density single crystal superalloy design. It will be shown that the best LDS alloy possesses the best attributes of three generations of single crystal alloys: the low density of first-generation single crystal alloys, the excellent oxidation resistance of second-generation single crystal alloys, and a creep strength which exceeds that of second and third generation alloys.

MacKay, Rebecca A.↗

Improving turbine blade fatigue life

Turbine airfoil design, materials, and cooling system management are variables which, when optimized, can contribute to longer turbine component lives. These advancements have been identified as redesign techniques to improve the turbine fatigue life of the SSME High Pressure Fuel Turbopump. This paper discusses the general program approach toward improving turbine fatigue life.

Buddenbohm, H. W.↗

Effect of Chord Size on Weight and Cooling Characteristics of Air-Cooled Turbine Blades

An analysis has been made to determine the effect of chord size on the weight and cooling characteristics of shell-supported, air-cooled gas-turbine blades. In uncooled turbines with solid blades, the general practice has been to design turbines with high aspect ratio (small blade chord) to achieve substantial turbine weight reduction. With air-cooled blades, this study shows that turbine blade weight is affected to a much smaller degree by the size of the blade chord.

Esgar, Jack B↗

Low-speed wind tunnel investigation of the static stability and control characteristics of an advanced turboprop configuration with the propellers placed over the tail

An exploratory wind tunnel investigation was performed in the 30 x 60 foot wind tunnel to determine the low speed static stability and control characteristics into the deep stall regime of an advanced turboprop aircraft with the propellers located over the horizontal tail. By this arrangement, the horizontal tail could potentially provide acoustic shielding to reduce the high community noise caused by the propeller blades. The current configuration was a generic turboprop model equipped with 1 foot diameter single rotating eight bladed propellers that were designed for efficient cruise operation at a Mach number of 0.8. The data presented is static force data. The effects of power on the configuration characteristics were generally favorable. An arrangement with the propellers rotating with the outboard blades moving down was found to have significantly higher installed thrust than an arrangement with the propellers rotating with the inboard blades moving down. The primary unfavorable effect was a large pitch trim change which occurred with power, but the trim change could be minimized with a proper configuration design.

Rhodes, Graham Scott↗

Highly loaded multi-stage fan drive turbine - performance of initial seven configurations

Experimental results of a three-stage highly loaded fan drive turbine test program are presented. A plain blade turbine, a tandem blade turbine, and a tangentially leaned stator turbine were designed for the same velocity diagram and flowpath. Seven combinations of bladerows were tested to evaluate stage performances and effects of the tandem blading and leaned stator. The plain blade turbine design point total-to-total efficiency was 0.886. The turbine with the stage three leaned stator had the same efficiency with an improved exit swirl profile and increased hub reaction. Two-stage group tests showed that the two-stage turbine with tandem stage two stator had an efficiency of 0.880 compared to 0.868 for the plain blade two-stage turbine.

Wolfmeyer, G. W.↗

Healable Coatings as a Mechanism to Repair Leading Edge Erosion in Wind Energy

Wind turbine blades are highly engineered structures designed to face temperature extremes and high winds. However, erosion of the blade's leading edge and subsequent repair remains a significant and costly challenge for the wind energy industry. Repair of these leading edges can lead to large amounts of downtime for the turbine and significant operational inefficiencies. In this work, the strength of adhesion and healing ability of a commercially available vitrimer (Mallinda's VITRIMAX) was compared to that of a thermoplastic resin, which has previously been demonstrated in wind energy applications (Arkema's Elium) to evaluate their efficacy as surface coatings for wind turbine blades, particularly their leading edges. Vitrimers are a class of inherently reprocessable thermosets, and it was theorized that vitrimer-based leading edge coatings could enable more robust and efficient wind turbine blades with decreased operational downtime and safer maintenance practices. It was found that the VITRIMAX adhered better to the wind blades' surfaces than both the manufacturer's paint and Elium, with increases in pull-off strength of adhesion ranging from 24% to 83% above that of the original paint. Furthermore, the VITRIMAX adhered strongly to the underlying composite of each blade with strength of adhesion values increasing in ranges from 42% to 97% above that of the original paint. Finally, the vitrimer coating showed an 88% decrease in surface roughness compared to end-of-life blade materials, and initial healing demonstrations in which coatings were manually scratched and subsequently healed exhibited an ~84.5% decrease in scratch depths.

Hubbard, Amber [ORNL]↗

Small axial compressor technology, volume 1

A scaled single-stage, highly-loaded, axial-flow transonic compressor was tested at speeds from 70 to 110% design equivalent speed to evaluate the effects of scaling compromises and the individual and combined effects of rotor tip running clearance and rotor shroud casing treatment on the overall and blade element performance. At design speed and 1% tip clearance the stage demonstrated an efficiency of 83.2% at 96.4% design flow and a pressure ratio of 1.865. Casing treatment increased design speed surge margin 2.0 points to 12.8%. Overall performance was essentially unchanged. An increase in rotor running clearance to 2.2%, with smooth casing, reduced design speed peak efficiency 5.7 points, flow by 7.4%, pressure ratio to 1.740, and surge margin to 5.4%. Reinstalling casing treatment regained 3.5 points in design speed peak efficiency, 4.7% flow, increased pressure ratio to 1.800 and surge margin to 8.7%.

Holman, F. F.↗