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NASA NTRS2009

Actively Controlled Components

Active Control can help to meet future engine requirements by an active improvement of the component characteristics. The concept is based on an intelligent control logic, which senses actual operating conditions and reacts with adequate actuator action. This approach can directly improve engine characteristics as performance, operability, durability and emissions on the one hand. On the other hand active control addresses the design constrains imposed by unsteady phenomena like inlet distortion, compressor surge, combustion instability, flow separations, vibration and noise, which only occur during exceptional operating conditions. The feasibility and effectiveness of active control technologies have been demonstrated in lab-scale tests. This chapter describes a broad range of promising applications for each engine component. Significant efforts in research and development remain to implement these technologies in engine rig and finally production engines and to demonstrate today s engine generation airworthiness, safety, reliability, and durability requirements. Active control applications are in particular limited by the gap between available and advanced sensors and actuators, which allow an operation in the harsh environment in an aero engine. The operating and performance requirements for actuators and sensors are outlined for each of the gas turbine sections from inlet to nozzle.

W. Horn↗

NASA NTRS2012

Testing of a Liquid Oxygen/Liquid Methane Reaction Control Thruster in a New Altitude Rocket Engine Test Facility

A relocated rocket engine test facility, the Altitude Combustion Stand (ACS), was activated in 2009 at the NASA Glenn Research Center. This facility has the capability to test with a variety of propellants and up to a thrust level of 2000 lbf (8.9 kN) with precise measurement of propellant conditions, propellant flow rates, thrust and altitude conditions. These measurements enable accurate determination of a thruster and/or nozzle s altitude performance for both technology development and flight qualification purposes. In addition the facility was designed to enable efficient test operations to control costs for technology and advanced development projects. A liquid oxygen-liquid methane technology development test program was conducted in the ACS from the fall of 2009 to the fall of 2010. Three test phases were conducted investigating different operational modes and in addition, the project required the complexity of controlling propellant inlet temperatures over an extremely wide range. Despite the challenges of a unique propellant (liquid methane) and wide operating conditions, the facility performed well and delivered up to 24 hot fire tests in a single test day. The resulting data validated the feasibility of utilizing this propellant combination for future deep space applications.

Meyer, Michael L.↗

NASA NTRS1977

Advances in laser technology for the atmospheric sciences; Proceedings of the Seminar, San Diego, Calif., August 25, 26, 1977

These papers deal with recent research, developments, and applications in laser and electrooptics technology, particularly with regard to atmospheric effects in imaging and propagation, laser instrumentation and measurements, and particle measurement. Specific topics include advanced imaging techniques, image resolution through atmospheric turbulence over the ocean, an efficient method for calculating transmittance profiles, a comparison of a corner-cube reflector and a plane mirror in folded-path and direct transmission through atmospheric turbulence, line-spread instrumentation for propagation measurements, scaling laws for thermal fluctuations in the layer adjacent to ocean waves, particle sizing by laser photography, and an optical Fourier transform analysis of satellite cloud imagery. Other papers discuss a subnanosecond photomultiplier tube for laser application, holography of solid propellant combustion, diagnostics of turbulence by holography, a camera for in situ photography of cloud particles from a hail research aircraft, and field testing of a long-path laser transmissometer designed for atmospheric visibility measurements.

Trolinger, J. D.↗

NASA NTRS1994

Combustor technology for future small gas turbine aircraft

To enhance fuel efficiency, future advanced small gas turbine engines will utilize engine cycles calling for overall engine pressure ratios, leading to higher combustor inlet pressures and temperatures. Further, the temperature rise through the combustor and the corresponding exit temperature are also expected to increase. This report describes future combustor technology needs for small gas turbine engines. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is anticipated in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors. Due to combustor size considerations, staged combustion is more easily accommodated in large engines. The inclusion of staged combustion in small engines will pose greater combustor design challenges.

Lyons, Valerie J.↗

NASA NTRS1999

Monte Carlo Simulation of Nanoparticle Encapsulation in Flames

Gas-phase combustion (flame) synthesis has been an essential industrial process for producing large quantities of powder materials such as carbon black, titanium dioxide, and silicon dioxide. Flames typically produce simple oxides, with carbon black being the noted exception because the oxides of carbon are gaseous and are easily separated from the particulate matter that is formed during fuel pyrolysis. Furthermore, the powders produced in flames are usually agglomerated, nanometer-sized particles (nanoparticles). This composition and morphology is acceptable for many applications. However, the present interest in nanoparticles for advanced materials application has led to efforts to employ flames for the synthesis of unagglomerated nanoparticles (2 to 100 nm) of metals and non-oxide ceramics. Sodium-halide chemistry has proven to be viable for producing metals and non-oxide ceramics in flames. Materials that have been produced to date include Si (Calcote and Felder, 1993), TiN, TiB2, TiC, TiSi2, SiC, B4C (Glassman et al, 1993) Al, W, Ti, TiB2, AlN, and W-Ti and Al-AlN composites (DuFaux and Axelbaum, 1995, Axelbaum et al 1996,1997). Many more materials are possible. The main challenge that faces application of flame synthesis for advanced materials is overcoming formation of agglomerates in flames (Brezinsky, 1997). The high temperatures and high number densities in the flame environment favor the formation of agglomerates. Agglomerates must be avoided for many reasons. For example, when nanopowders are consolidated, agglomerates have a deleterious effect on compaction density, leading to voids in the final part. Efforts to avoid agglomeration in flames without substantially reducing particle number density and, consequently, production rate, have had limited success. Another critical challenge that faces all synthesis routes for nanopowders is ensuring that the powders are high purity and that the process is scaleable. Though the containerless, high temperature environment of a flame is excellent for producing high-purity simple compounds, ultrafine metals and non-oxide ceramic powders are inherently reactive in the presence of oxygen and/or moisture. Thus, the handling of these powders after synthesis poses a challenging problem. Impurities acquired during handling of nanoparticles have plagued the advancement of nanostructured materials technology.

Sun, Z.↗

NASA NTRS1999

Detailed Multidimensional Simulations of the Structure and Dynamics of Flames

Numerical simulations in which the various physical and chemical processes can be independently controlled can significantly advance our understanding of the structure, stability, dynamics and extinction of flames. Therefore, our approach has been to use detailed time-dependent, multidimensional, multispecies numerical models to perform carefully designed computational experiments of flames on Earth and in microgravity environments. Some of these computational experiments are complementary to physical experiments performed under the Microgravity Program while others provide a fundamental understanding that cannot be obtained from physical experiments alone. In this report, we provide a brief summary of our recent research highlighting the contributions since the previous microgravity combustion workshop. There are a number of mechanisms that can cause flame instabilities and result in the formation of dynamic multidimensional structures. In the past, we have used numerical simulations to show that it is the thermo-diffusive instability rather than an instability due to preferential diffusion that is the dominant mechanism for the formation of cellular flames in lean hydrogen-air mixtures. Other studies have explored the role of gravity on flame dynamics and extinguishment, multi-step kinetics and radiative losses on flame instabilities in rich hydrogen-air flames, and heat losses on burner-stabilized flames in microgravity. The recent emphasis of our work has been on exploring flame-vortex interactions and further investigating the structure and dynamics of lean hydrogen-air flames in microgravity. These topics are briefly discussed after a brief discussion of our computational approach for solving these problems.

Patnaik, G.↗

NASA NTRS2013

Development of Large-Scale Spacecraft Fire Safety Experiments

The status is presented of a spacecraft fire safety research project that is under development to reduce the uncertainty and risk in the design of spacecraft fire safety systems by testing at nearly full scale in low-gravity. Future crewed missions are expected to be more complex and longer in duration than previous exploration missions outside of low-earth orbit. This will increase the challenge of ensuring a fire-safe environment for the crew throughout the mission. Based on our fundamental uncertainty of the behavior of fires in low-gravity, the need for realistic scale testing at reduced gravity has been demonstrated. To address this gap in knowledge, a project has been established under the NASA Advanced Exploration Systems Program under the Human Exploration and Operations Mission directorate with the goal of substantially advancing our understanding of the spacecraft fire safety risk. Associated with the project is an international topical team of fire experts from other space agencies who conduct research that is integrated into the overall experiment design. The experiments are under development to be conducted in an Orbital Science Corporation Cygnus vehicle after it has undocked from the ISS. Although the experiment will need to meet rigorous safety requirements to ensure the carrier vehicle does not sustain damage, the absence of a crew removes the need for strict containment of combustion products. The tests will be fully automated with the data downlinked at the conclusion of the test before the Cygnus vehicle reenters the atmosphere. A computer modeling effort will complement the experimental effort. The international topical team is collaborating with the NASA team in the definition of the experiment requirements and performing supporting analysis, experimentation and technology development. The status of the overall experiment and the associated international technology development efforts are summarized.

Life Support↗

NASA NTRS2017

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiC-SiC Ceramic Matrix Composite (CMC) combustors particularly under the NASA Environmentally Responsible Aviation, Fundamental Aeronautics and Transformative Aeronautics Concepts Programs. The emphases have been placed on the current design challenges of the 2700-3000F capable environmental barrier coatings for low NOX emission combustors for next generation turbine engines by using advanced plasma spray based processes, and the coating processing and integration with SiC-SiC CMCs and component systems. The developments also have included candidate coating composition system designs, degradation mechanisms, performance evaluation and down-selects; the processing optimizations using TriplexPro Air Plasma Spray Low Pressure Plasma Spray (LPPS), Plasma Spray Physical Vapor Deposition and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements under the NASA development programs, as demonstrated in the simulated engine high heat flux, combustion environments, in conjunction with high heat flux, mechanical creep and fatigue loading testing conditions.

CMAS↗

NASA NTRS1993

Advanced Small Rocket Chambers. Basic Program and Option 2: Fundamental Processes and Material Evaluation

Propellants, chamber materials, and processes for fabrication of small high performance radiation cooled liquid rocket engines were evaluated to determine candidates for eventual demonstration in flight-type thrusters. Both storable and cryogenic propellant systems were considered. The storable propellant systems chosen for further study were nitrogen tetroxide oxidizer with either hydrazine or monomethylhydrazine as fuel. The cryogenic propellants chosen were oxygen with either hydrogen or methane as fuel. Chamber material candidates were chemical vapor deposition (CVD) rhenium protected from oxidation by CVD iridium for the chamber hot section, and film cooled wrought platinum-rhodium or regeneratively cooled stainless steel for the front end section exposed to partially reacted propellants. Laser diagnostics of the combustion products near the hot chamber surface and measurements at the surface layer were performed in a collaborative program at Sandia National Laboratories, Livermore, CA. The Material Sample Test Apparatus, a laboratory system to simulate the combustion environment in terms of gas and material temperature, composition, and pressure up to 6 Atm, was developed for these studies. Rocket engine simulator studies were conducted to evaluate the materials under simulated combustor flow conditions, in the diagnostic test chamber. These tests used the exhaust species measurement system, a device developed to monitor optically species composition and concentration in the chamber and exhaust by emission and absorption measurements.

Jassowski, Donald M.↗

NASA NTRS1985

Combustion research for gas turbine engines

Research on combustion is being conducted at Lewis Research Center to provide improved analytical models of the complex flow and chemical reaction processes which occur in the combustor of gas turbine engines and other aeropropulsion systems. The objective of the research is to obtain a better understanding of the various physical processes that occur in the gas turbine combustor in order to develop models and numerical codes which can accurately describe these processes. Activities include in-house research projects, university grants, and industry contracts and are classified under the subject areas of advanced numerics, fuel sprays, fluid mixing, and radiation-chemistry. Results are high-lighted from several projects.

Mularz, E. J.↗

NASA NTRS1985

Combustion research for gas turbine engines

Mularz, E. J.↗

NASA NTRS2017

The Quest for Engineering Innovation at NASA's Marshall Space Flight (MSFC)

A recent NASA team, chartered to examine innovation within the Agency, captured the meaning of the word innovation as the "application of creative ideas to improve and generate value for the organization". The former NASA Administrator Charles Bolden shared his own thoughts about innovation in a memo with all employees that stated, "At NASA, we are dedicated to innovation, bold ideas, and excellence." Innovation turns out to be one of the major driving forces behind the work produced at NASA. It seems failure is often what has driven NASA to be more innovative. Fifty years ago, the Apollo 1 tragedy killed three astronauts when fire erupted in their command module. NASA had to bear the responsibility of such loss and at the same time work smarter in order to obtain the dream to reach the moon by the end of the 1960s. Through this circumstance, NASA engineers developed a revolutionary replacement for the combustible nylon astronaut suits so the Apollo program could continue. A material called Beta Cloth was born. This material was used to produce noncombustible space suits for all Apollo astronauts, enabling the United States to ultimately land 12 Americans on the moon. Eventually this material was used as the roof system in the Denver International Airport, showing relevance and applications of NASA innovations to real-world need. Innovative ideas are also driven by the need to accomplish NASA missions and to improve the way we produce our products. MSFC engineers are advancing technologies in additive manufacturing of liquid rocket engines in order to reduce the number of parts, design time, and the cost of the engines. NASA is working with academia to eliminate the need for miles of sensor cables by investigating innovations in wireless sensors. In order to enable future exploration missions to Mars, MSFC engineers are pursuing innovative approaches in diverse areas such as the use of ionic liquids for life support systems and composite cryogenic tanks, very low leakage valves to contain propulsion fluids, and natural, non-toxic inhibitors to eliminate the buildup of biofilms in the water systems planned for future crewed Mars missions. Although results are encouraging, we cannot rest on our past accomplishments. In order to overcome breathtaking technical challenges in space exploration, we must continue to promote a culture supporting growth, breakthroughs and disruptive innovations.

Turner, James E.↗

NASA NTRS2003

Advanced Signal Processing for Integrated LES-RANS Simulations: Anti-aliasing Filters

Currently, a wide variety of flow phenomena are addressed with numerical simulations. Many flow solvers are optimized to simulate a limited spectrum of flow effects effectively, such as single parts of a flow system, but are either inadequate or too expensive to be applied to a very complex problem. As an example, the flow through a gas turbine can be considered. In the compressor and the turbine section, the flow solver has to be able to handle the moving blades, model the wall turbulence, and predict the pressure and density distribution properly. This can be done by a flow solver based on the Reynolds-Averaged Navier-Stokes (RANS) approach. On the other hand, the flow in the combustion chamber is governed by large scale turbulence, chemical reactions, and the presence of fuel spray. Experience shows that these phenomena require an unsteady approach. Hence, for the combustor, the use of a Large Eddy Simulation (LES) flow solver is desirable. While many design problems of a single flow passage can be addressed by separate computations, only the simultaneous computation of all parts can guarantee the proper prediction of multi-component phenomena, such as compressor/combustor instability and combustor/turbine hot-streak migration. Therefore, a promising strategy to perform full aero-thermal simulations of gas-turbine engines is the use of a RANS flow solver for the compressor sections, an LES flow solver for the combustor, and again a RANS flow solver for the turbine section.

Schlueter, J. U.↗

NASA NTRS1993

Combustor technology for future small gas turbine aircraft

Future engine cycles proposed for advanced small gas turbine engines will increase the severity of the operating conditions of the combustor. These cycles call for increased overall engine pressure ratios which increase combustor inlet pressure and temperature. Further, the temperature rise through the combustor and the corresponding exit temperature also increase. Future combustor technology needs for small gas turbine engines is described. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is expected in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors.

Lyons, Valerie J.↗

NASA NTRS1976

Advanced Low NOx Combustors for Aircraft Gas Turbines

A test rig program was conducted with the objective of evaluating and minimizing the exhaust emissions, in particular NOx, of two advanced aircraft combustor concepts at a simulated high-altitude cruise condition. The two pre-mixed, lean-reaction designs are known as the Jet Induced Circulation (JIC) combustor and the Vortex Air Blast (VAB) combustor and were rig tested in the form of reverse flow can combustors in the 0.13 ni (5.0 in. ) size range. Various configuration modifications were applied to the JIC and VAB combustor designs in an effort to reduce the emissions levels. The VAB combustor demonstrated a NOx level of 1.11 gm NO2/kg fuel with essentially 100 percent combustion efficiency at the simulated cruise combustor condition of 507 kPa (5 atm), 833 K (1500 R), inlet pressure and temperature respectively, and 1778 K (3200 R) outlet temperature on Jet-Al fuel. These configuration screening tests were carried out on essentially reaction zones only, in order to simplify the construction and modification of the combustors and to uncouple any possible effects on the emissions produced by the dilution flow. Tests were also conducted however at typical engine idle conditions on both combustors equipped with dilution ports in order to better define the problem areas involved in the operation of such concepts over a complete engine operational envelope. Versions of variable-geometry, JIC and VAB annular combustors are proposed.

Roberts, P. B.↗

NASA NTRS2007

Multiple-Parameter, Low-False-Alarm Fire-Detection Systems

Fire-detection systems incorporating multiple sensors that measure multiple parameters are being developed for use in storage depots, cargo bays of ships and aircraft, and other locations not amenable to frequent, direct visual inspection. These systems are intended to improve upon conventional smoke detectors, now used in such locations, that reliably detect fires but also frequently generate false alarms: for example, conventional smoke detectors based on the blockage of light by smoke particles are also affected by dust particles and water droplets and, thus, are often susceptible to false alarms. In contrast, by utilizing multiple parameters associated with fires, i.e. not only obscuration by smoke particles but also concentrations of multiple chemical species that are commonly generated in combustion, false alarms can be significantly decreased while still detecting fires as reliably as older smoke-detector systems do. The present development includes fabrication of sensors that have, variously, micrometer- or nanometer-sized features so that such multiple sensors can be integrated into arrays that have sizes, weights, and power demands smaller than those of older macroscopic sensors. The sensors include resistors, electrochemical cells, and Schottky diodes that exhibit different sensitivities to the various airborne chemicals of interest. In a system of this type, the sensor readings are digitized and processed by advanced signal-processing hardware and software to extract such chemical indications of fires as abnormally high concentrations of CO and CO2, possibly in combination with H2 and/or hydrocarbons. The system also includes a microelectromechanical systems (MEMS)-based particle detector and classifier device to increase the reliability of measurements of chemical species and particulates. In parallel research, software for modeling the evolution of a fire within an aircraft cargo bay has been developed. The model implemented in the software can describe the concentrations of chemical species and of particulate matter as functions of time. A system of the present developmental type and a conventional fire detector were tested under both fire and false-alarm conditions in a Federal Aviation Administration cargo-compartment- testing facility. Both systems consistently detected fires. However, the conventional fire detector consistently generated false alarms, whereas the developmental system did not generate any false alarms.

Hunter, Gary W.↗

NASA NTRS2016

Overcoming the Adoption Barrier to Electric Flight

Electrically-powered aircraft can enable dramatic increases in efficiency and reliability, reduced emissions, and reduced noise as compared to today's combustion-powered aircraft. This paper describes a novel flight demonstration concept that will enable the benefits of electric propulsion, while keeping the extraordinary convenience and utility of common fuels available at today's airports. A critical gap in airborne electric propulsion research is addressed by accommodating adoption at the integrated aircraft-airport systems level, using a confluence of innovative but proven concepts and technologies in power generation and electricity storage that need to reside only on the airframe. Technical discriminators of this demonstrator concept include (1) a novel, high-efficiency power system that utilizes advanced solid oxide fuel cells originally developed for ultra-long-endurance aircraft, coupled with (2) a high-efficiency, high-power electric propulsion system selected from mature products to reduce technical risk, assembled into (3) a modern, high-performance demonstration platform to provide useful and compelling data, both for the targeted early adopters and the eventual commercial market.

Borer, Nicholas K.↗

NASA NTRS2004

Environmental Barrier Coatings for Ceramics and Ceramic Composites

One key factor that limits the performance of current gas turbine engines is the temperature capability of hot section structural components. Silicon-based ceramics, such as SiC/SiC composites and monolithic Si3N4, are leading candidates to replace superalloy hot section components in the next generation gas turbine engines due to their excellent high temperature properties. A major stumbling block to realizing Si-based ceramic hot section components is the recession of Si-based ceramics in combustion environments due to the volatilization of silica scale by water vapor. An external environmental barrier coating (EBC) is the most promising approach to preventing the recession. Current EBCs are based on silicon, mullite (3A12O3-2SiO2) and BSAS (barium strontium aluminum silicate with celsian structure). Volatility of BSAS, BSAS-silica chemical reaction, and low melting point of silicon limit the durability and temperature capability of current EBCs. Research is underway to develop EBCs with longer life and enhanced temperature capability. Understanding key issues affecting the performance of current EBCs is necessary for successful development of advanced EBCs. These issues include stress, chemical compatibility, adherence, and water vapor stability. Factors that affect stress are thermal expansion mismatch, phase stability, chemical stability, elastic modulus, etc. The current understanding on these issues will be discussed.

Lee, Kang N.↗