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At least 847 records · Page 47

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NASA NTRS1981

Improving turbine engine compressor performance retention through airfoil coatings

In order to evaluate the potential effectiveness of coatings in limiting erosive damage to compressor airfoils, an effort was initiated to evaluate candidate coatings for substrate alloys typically used in commercial engine high compressor blades. Laboratory and rig erosion testing of plasma deposited and diffusion coatings described in this paper have shown the potential of a two to four fold improvement in erosion life. The selective application of these coatings to approximately the outer third of the airfoil avoids coating the fatigue critical region of the blade, thus providing erosion resistance potentially without compromising the fatigue strength of the blade. Both the plasma and the diffusion coatings also offer the advantage of low initial cost and a multi-source production base.

Friedrich, L. A.↗

NASA NTRS1981

Computer program for pulsed thermocouples with corrections for radiation effects

A pulsed thermocouple was used for measuring gas temperatures above the melting point of common thermocouples. This was done by allowing the thermocouple to heat until it approaches its melting point and then turning on the protective cooling gas. This method required a computer to extrapolate the thermocouple data to the higher gas temperatures. A method that includes the effect of radiation in the extrapolation is described. Computations of gas temperature are provided, along with the estimate of the final thermocouple wire temperature. Results from tests on high temperature combustor research rigs are presented.

Will, H. A.↗

NASA NTRS1980

Thermal barrier coatings for heat engine components

A comprehensive NASA-Lewis program of coating development for aircraft gas turbine blades and vanes is presented. Improved ceramic layer compositions are investigated, along the MCrAlY bond films and the methods of uniform deposition of the coatings; the thermomechanical and fuel impurity tolerance limits of the coatings are being studied. Materials include the ZrO2-Y2O3/NiCrAlY system; the effects of the bond coat and zirconia composition on coating life and Mach 1 burner rig test results are discussed. It is concluded that Diesel engines can also utilize thermal barrier coatings; they have been used successfully on piston crowns and exhaust valves of shipboard engines to combat lower grade fuel combustion corrosion.

Levine, S. R.↗

NASA NTRS1981

Development of a low NO/x/ lean premixed annular combustor

The results of an experimental atmospheric rig test program developed to define a low NO(x) annular combustor of 0.66 m diameter for high-altitude aircraft applications are presented. The test program strategy adopted evaluates the emission characteristics of a baseline configuration and subsequently examines the sensitivity of the emission signatures to variations in the key design features. The lean premixed combustor in axisymmetric annular form demonstrates the capability of operating at reduced-pressure, simulated high-altitude, supersonic cruise conditions with NO(x) emissions below 1.0 g NO2/kg fuel. The testing shows that for the full range of low emissions operation from idle to cruise, a variable dilution port system is necessary, but that fuel-switching can be avoided and a single fuel injection system used.

Roberts, P. B.↗

NASA NTRS1981

Low NO/x/ and fuel flexible gas turbine combustors

The feasibility of various low NO(x) emission gas turbine combustor configurations was evaluated. The configurations selected for fabrication and testing at full pressure and temperature involved rich-lean staged combustion utilizing diffusion flames, rich-lean prevaporized/premix flames, and staged catalytic combustion. The test rig consisted of a rich burner module, a quench module, and a lean combustion module. Test results are obtained for the combustor while burning petroleum distillate fuel, a coal derived liquid, and a petroleum residual fuel. The results indicate that rich-lean diffusion flames with low fuel-bound nitrogen conversion are achievable with very high combustion efficiencies.

Lew, H. G.↗

NASA NTRS1981

Low NO/x/ combustion systems for burning heavy residual fuels and high-fuel-bound nitrogen fuels

Design concepts are presented for lean-lean and staged rich-lean combustors. The combustors are designed for the dry reduction of thermal NO(x), control of NO(x) from fuels containing high levels of organic nitrogen, and control of smoke from low hydrogen content fuels. The combustor concepts are tested with a wide variety of fuels including a middle distillate, a petroleum based heavy residual, a coal derived synthetic, and ratios of blends of these fuels. The configurations of the lean-lean and rich-lean combustion systems are provided along with a description of the test rig and test procedure.

White, D. J.↗

NASA NTRS1981

Thermal and stress analysis of thermal barrier coatings

An analysis has been performed that predicts the thermomechanical behavior of thermal barrier coated specimens. The analysis predicts the behavior during both plasma spray coating application and burner rig testing conditions simulating engine operation. The analysis was accomplished through utilization of one-dimensional through thickness and two-dimensional finite element calculations. The results of these calculations showed that specimens with a substrate control temperature between 300 F and 600 F would be optimum. Controlling substrate temperature was found to have a more dominant effect on the mechanical strains than the ceramic or substrate thicknesses. The predicted stresses and mechanical strains at the bond-coating interface are large enough to cause cracks in this region where post-test observations have determined coating failures originate.

Cassenti, B. N.↗

NASA NTRS1981

The design and development of a mixer compound exhaust system for a quiet clean general aviation turbofan

Lower engine fuel consumption has become a dominant factor in turbofan engine design due to rapidly increasing fuel costs. One engine component with a large impact on engine performance is the exhaust system. Previous exhaust system studies have demonstrated the significant exhaust system efficiency gains available through mixing of the core and bypass flows. Typically, a large, costly rig and engine program are required to develop and optimize these gains. The purpose of this paper is to present the results of the low-cost design system used for the quiet, clean general aviation turbofan mixer nozzle design and development. The scale model and full-scale engine test results confirm the predicted 3 to 5% reduction in cruise fuel consumption. This unique design system, which is based on integrating advanced three-dimensional viscous numerical methods with empirical optimization techniques, is summarized and detailed comparisons with test data are presented. The ability to accurately predict relative performance of mixer systems with substantially reduced development time and cost savings is demonstrated.

Blackmore, W. L.↗

NASA NTRS1981

Development of energy-absorbing reaction-sintered Si3N4 surface layers on hot-pressed Si3N4

Energy-absorbing Si3N4 surface layers on dense Si3N4 substrates were formed by in-place nitridation of fine-grained silicon powder. Ballistic impact tests performed on samples with 1-mm thick layers at room temperature and 1370 C showed up to an eightfold increase in the energy necessary to fracture the substrate. For maximum impact resistance, a small amount (about 20 vol %) of residual Si must be present in the reaction-sintered Si3N4 surface layer. Thermal cycling to 1370 C did not affect impact resistance, even though a considerable amount of SiO2 formed within the reaction-sintered Si3N4 layer during cycling. Erosion testing of samples in a Mach 0.8 burner rig at 1370 C resulted in minimal surface recession of the surface layer. Chemically vapor-deposited SiC-coated material similarly tested exhibited no surface recession.

Brennan, J. J.↗

NASA NTRS1983

Quick-Connect, Self-Alining Latch

Sturdy latch tolerates 10 degrees of angular mismatch in joining structural elements. Hexagonal passive plate nests in active plate, guided by capture plates and alinement keys and grooves. Center hole in both active and passive plates is 1 meter in diameter. Latch has possible uses a pipe joint, connector for parts of portable structures, and fitting for marine risers on offshore drilling rigs.

Burns, G. C.↗

NASA NTRS1981

Thermal-barrier-coated turbine blade study

The effects of coating TBC on a CF6-50 stage 2 high-pressure turbine blade were analyzed with respect to changes in the mean bulk temperature, cooling air requirements, and high-cycle fatigue. Localized spallation was found to have a possible deleterious effect on low-cycle fatigue life. New blade design concepts were developed to take optimum advantage of TBCs. Process and material development work and rig evaluations were undertaken which identified the most promising combination as ZrO2 containing 8 w/o Y2O3 applied by air plasma spray onto a Ni22Cr-10Al-1Y bond layer. The bond layer was applied by a low-pressure, high-velocity plasma spray process onto the base alloy. During the initial startup cycles the blades experienced localized leading edge spallation caused by foreign objects.

Siemers, P. A.↗

NASA NTRS1981

Pollution reduction technology program small jet aircraft engines, phase 3

A series of Model TFE731-2 engine tests were conducted with the Concept 2 variable geometry airblast fuel injector combustion system installed. The engine was tested to: (1) establish the emission levels over the selected points which comprise the Environmental Protection Agency Landing-Takeoff Cycle; (2) determine engine performance with the combustion system; and (3) evaulate the engine acceleration/deceleration characteristics. The hydrocarbon (HC), carbon monoxide (CO), and smoke goals were met. Oxides of nitrogen (NOx) were above the goal for the same configuration that met the other pollutant goals. The engine and combustor performance, as well as acceleration/deceleration characteristics, were acceptable. The Concept 3 staged combustor system was refined from earlier phase development and subjected to further rig refinement testing. The concept met all of the emissions goals.

Bruce, T. W.↗

NASA NTRS1981

Development of improved high temperature coatings for IN-792 + HF

The development for t-55 l712 engine of high temperature for integral turbine nozzles with improved thermal fatigue resistance without sacrificing oxidation/corrosion protection is discussed. The program evaluated to coating systems which comprised one baseline plasma spray coating (12% Al-NiCoCrALY), three aluminide coatings including the baseline aluminide (701), two CoNiCrAly (6% Al) + aluminide systems and four NiCoCrY + aluminide coating were evaluated. The two-step coating processes were investigated since it offered the advantage of tailoring the composition as well as properly coating surfaces of an integral or segmented nozzle. Cyclic burner rig thermal fatigue and oxidation/corrosion tests were used to evaluate the candidate coating systems. The plasma sprayed 12% Al-NiCoCrAlY was rated the best coating in thermal fatigue resistance and outperformed all coatings by a factor between 1.4 to 2.5 in cycles to crack initiation. However, this coatings is not applicable to integral or segmented nozzles due to the line of sight limitation of the plasma spray process. The 6% Al-CoNiCrAlY + Mod. 701 aluminide (32 w/o Al) was rated the best coating in oxidation/corrosion resistance and was rated the second best in thermal fatigue resistance.

Profant, D. D.↗

NASA NTRS1982

Comparison of acoustic data from a 102 mm conic nozzle as measured in the RAE 24-foot wind tunnel and the NASA Ames 40- by 80-foot wind tunnel

A cooperative program between the Royal Aircraft Establishment (RAE), England, and the NASA Ames Research Center was initiated to compare acoustic measurements made in the RAE 24-foot wind tunnel and in the Ames 40- by 80-foot wind tunnel. The acoustic measurements were made in both facilities using the same 102 mm conical nozzle supplied by the RAE. The nozzle was tested by each organization using its respective jet test rig. The mounting hardware and nozzle exit conditions were matched as closely as possible. The data from each wind tunnel were independently analyzed by the respective organization. The results from these tests show good agreement. In both facilities, interference with acoustic measurement is evident at angles in the forward quadrant.

Atencio, A., Jr.↗

NASA NTRS1981

Review of NASA progress in thermal barrier coatings for stationary gas turbines

Ceramic thermal barrier coatings for industrial/utility gas turbines were investigated. In burner rig tests of a zirconia yttria/nickel chromium aluminum yttrium ZrO2-12w/0Y2O3/NiCrAlY coating system on air cooled superalloy specimens, ceramic coating life (spallation) was sensitive to Na and V concentration in the fuel. The locations of coating spallation correspond to areas where combustion products were predicted to condense. Three new thermal barrier coating systems were identified. These are based on calcium silicate, ZrO2-8w/0Y2O3, and a MgO-NiCrAlY cermet. The spall resistance can be increased by reducing the ceramic layer thickness from 0.038 to 0.013 cm and by the use of more oxidation/corrosion resistant bond coats.

Hodge, P. E.↗

NASA NTRS1982

Evaluation of present thermal barrier coatings for potential service in electric utility gas turbines

The resistance of present-day thermal barrier coatings to combustion gases found in electric utility turbines was assessed. The plasma sprayed coatings, both duplex and graded types, were primarily zirconia-based, although a calcium silicate was also evaluated. Both atmospheric burner rig tests and high pressure tests (135 psig) showed that several present-day thermal barrier coatings have a high potential for service in gas turbines burning the relatively clean GT No. 2 fuel. However, coating improvements are needed for use in turbines burning lower grade fuel such as residual oil. The duplex ZrO2.8Y2O3/NiCrA1Y coating was ranked highest and selected for near-term field testing, with Ca2SiO4/NiCrA1Y ranked second. Graded coatings show potential for corrosive turbine operating conditions and warrant further development. The coating degradation mechanisms for each coating system subjected to the various environmental conditions are also described.

Bratton, R. J.↗

NASA NTRS1982

JT9D ceramic outer air seal system refinement program

The abradability and durability characteristics of the plasma sprayed system were improved by refinement and optimization of the plasma spray process and the metal substrate design. The acceptability of the final seal system for engine testing was demonstrated by an extensive rig test program which included thermal shock tolerance, thermal gradient, thermal cycle, erosion, and abradability tests. An interim seal system design was also subjected to 2500 endurance test cycles in a JT9D-7 engine.

Gaffin, W. O.↗

NASA NTRS1981

Tailored plasma sprayed MCrAlY coatings for aircraft gas turbine applications

Eighteen plasma sprayed coating systems, nine based on the NiCoCrAly chemistry and nine based on the CoCrAly composition, were evaluated to identify coating systems which provide equivalent or superior life to that shown by the electron beam physical vapor deposited NiCoCrAly and CoCrAly coatings respectively. NiCoCrAly type coatings were examined on a single crystal alloy and the CoCrAly based coatings were optimized on the B1900+ Hf alloy. Cyclic burner rig oxidation and hot corrosion and tensile ductility tests used to evaluate the various coating candidates. For the single crystal alloy, a low pressure chamber plasma sprayed NiCoCrAly + Si coating exhibited a 2x oxidation life improvement at 1394 K (2050 F) over the vapor deposited NiCoCrAly material while showing equivalent tensile ductility. A silicon modified low pressure chamber plasma sprayed CoCrAly coating was found to be more durable than the baseline vapor deposited CoCrAly coating on the B1900+ Hf alloy.

Pennisi, F. J.↗