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The internal noise generated by an Avco Lycoming YF-102 engine combustor installed in a test rig was recorded. The one third octave band pressure level spectra is presented.
The internal noise generated by an Avco Lycoming YF-102 engine combustor installed in a test rig was recorded. The narrow band pressure level spectra is presented.
Calibration tests using hot wires were conducted using a newly developed test rig that greatly reduced the data acquisition time. A comparison of measured and computed velocity vector magnitude and direction indicates the necessity of complete probe calibration to determine flow interference and/or operating limitation regions. Calibration results indicate that flow rates with 3 percent accuracy and flow angles with 5 deg accuracy are attainable.
The feasibility of using MERL 76, an advanced high strength direct hot isostatic pressed powder metallurgy superalloy, as a full scale component in a high technology, long life, commercial turbine engine were demonstrated. The component was a JT9D first stage turbine disk. The JT9D disk rim temperature capability was increased by at least 22 C and the weight of JT9D high pressure turbine rotating components was reduced by at least 35 pounds by replacement of forged Superwaspaloy components with hot isostatic pressed (HIP) MERL 76 components. The process control plan and acceptance criteria for manufacture of MERL 76 HIP consolidated components were generated. Disk components were manufactured for spin/burst rig test, experimental engine tests, and design data generation, which established lower design properties including tensile, stress-rupture, 0.2% creep and notched (Kt = 2.5) low cycle fatigue properties, Sonntag, fatigue crack propagation, and low cycle fatigue crack threshold data. Direct HIP MERL 76, when compared to conventionally forged Superwaspaloy, is demonstrated to be superior in mechanical properties, increased rim temperature capability, reduced component weight, and reduced material cost by at least 30% based on 1980 costs.
Rig tests of a can-type combustor were performed to demonstrate two advanced ground power engine combustor concepts: steam cooled rich-burn combustor primary zones for enhanced durability; and variable combustor geometry for three stage combustion equivalence ratio control. Both concepts proved to be highly successful in achieving their desired objectives. The steam cooling reduced peak liner temperatures to less than 800 K. This offers the potential of both long life and reduced use of strategic materials for liner fabrication. Three degrees of variable geometry were successfully implemented to control airflow distribution within the combustor. One was a variable blade angle axial flow air swirler to control primary airflow while the other two consisted of rotating bands to control secondary and tertiary or dilution air flow.
Catalytic combustion of both low and medium heating value gases using actual coal derived gases obtained from operating gasifiers was demonstrated. A fixed bed gasifier with a complete product gas cleanup system was operated in an air blown mode to produce low heating value gas. A fluidized bed gasifier with a water quench product gas cleanup system was operated in both an air enriched and an oxygen blown mode to produce low and medium, heating value gas. Noble metal catalytic reactors were evaluated in 12 cm flow diameter test rigs on both low and medium heating value gases. Combustion efficiencies greater than 99.5% were obtained with all coal derived gaseous fuels. The NOx emissions ranged from 0.2 to 4 g NO2 kg fuel.
A digital optical torquemeter system designed for applications at high rotational speeds was fabricated and tested for zero stability at speeds up to 20,000 rpm. Data obtained in a spin rig and with simulated inputs demonstrate that the system is capable of measuring torque bar twist to within 0.03 degrees at speeds of 30,000 rpm. The optical system uses fiber optic bundles to transmit light to the torque bar and to silicon avalanche detectors. The system is microcomputer based and provides measurements of average torque and torque as a function of angular shaft position. The torquemeter requires no bearings or other contact between the rotating torque bar and the nonrotating optics, and tolerates movement of the torque bar as large as 1 mm relative to the optics.
A program was conducted with the objective of developing advanced thermal barrier coating (TBC) systems. Coating application was by plasma spray. Duplex, triplex and graded coatings were tested. Coating systems incorporated both NiCrAly and CoCrAly bond coats. Four ceramic overlays were tested: ZrO2.82O3; CaO.TiO2; 2CaO.SiO2; and MgO.Al2O3. The best overall results were obtained with a CaO.TiO2 coating applied to a NiCrAly bond coat. This coating was less sensitive than the ZrO2.8Y2O3 coating to process variables and part geometry. Testing with fuels contaminated with compounds containing sulfur, phosphorus and alkali metals showed the zirconia coatings were destabilized. The calcium titanate coatings were not affected by these contaminants. However, when fuels were used containing 50 ppm of vanadium and 150 ppm of magnesium, heavy deposits were formed on the test specimens and combustor components that required frequent cleaning of the test rig. During the program Mars engine first-stage turbine blades were coated and installed for an engine cyclic endurance run with the zirconia, calcium titanate, and calcium silicate coatings. Heavy spalling developed with the calcium silicate system. The zirconia and calcium titanate systems survived the full test duration. It was concluded that these two TBC's showed potential for application in gas turbines.
In reviewing the progress made in acoustic measurements in wind tunnels over the 5-yr span of the workshops, it is evident that a great deal of progress has occurred. Specialized facilities are now on line, special measurement techniques were developed, and corrections were devised and proven. This capability is in the process of creating a new and more correct data bank on acoustic phenomena, and represents a major step forward in acoustics technology. Additional work is still required, but now, rather than concentrating on facilities and techniques, researchers may more profitably concentrate on noise-source modeling, with the simulation of propulsor noise source (in flight) and of propulsor/airframe airflow characteristics. Promising developments in directional acoustic receivers and other discrimination/correlation techniques should now be regularly exploited, in part for model noise-source diagnosis, but also to expedite extraction of the lone source signal from any residual background noise and reverberation in the working chamber and from parasitic noise due to essential rigs or instrumentation inside the airstream.
Flight control systems and aerodynamic aspects of experimental V/STOL aircraft are discussed. The VJ 101 C featured tilting engines for increased thrust, reheat for takeoff, simple translation, triangular decentralization of the engines for thrust modulation, and moderate ground effects. Two experimental aircraft were built, with and without reheat, capable of Mach 2 and Mach 1.04, respectively. The mechanical flight control system and tests are outlined, both for hover rig and flight configurations. Ground suction, acoustic and thermal loading, sodium silicate coatings to avoid ground corrosion, and recirculation are considered. Results of the follow-on project to the VJ 101 C, the AVS, which was developed by NASA, are reviewed, and it is noted that trends toward thrust-to-weight ratios exceeding one, in concert with low wing loading, favor the development of V/STOL aircraft.
Results are presented from an experimental program aimed at optimizing the features of an advanced two-stage combustor that currently is being developed as part of the National Aeronautics and Space Administration/Pratt & Whitney Aircraft Energy Efficient Engine program. The combustor is designed to meet stringent goals for performance, emissions, durability and operational characteristics. An overview of the design selection process in light of these goals is discussed. Combustor rig test results, which highlight the techniques used to reduce emissions, development of the pilot and main power zone fuel injection systems, and methods of achieving efficient fuel staging, are presented.
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 will 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 were 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 1121 C (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.
Cyclic furnace and cyclic natural gas-oxygen torch rig tests were conducted to (1) identify a thermal-barrier system for a nickel-aluminum-molybdenum alloy, (2) study the oxidation of the bond coating, and (3) study the effect of the substrate coefficient of thermal expansion on thermal barrier system life. It is found that the latter is affected by the composition of the bond coating, yttria concentration in zirconia, and the coefficient of thermal expansion of the substrate material. In addition, small compositional changes in the bond and thermal barrier coatings have greater effect on thermal barrier system life than the 40% increase in the coefficient of thermal expansion of the substrate material. No simple relation exists between the weight gain caused by bond-coating oxidation with increasing yttria concentration in zirconia and increasing bond coating thickness on the one hand, and thermal barrier system life on the other.
In connection with increases in the cost of fuels and the reduced availability of high quality petroleum crude, a modification of fuel specifications has been considered to allow acceptance of poorer quality fuels. To obtain the information upon which a selection of appropriate fuels for aircraft can be based, the Broad Specification Fuels Combustion Technology program was formulated by NASA. A description is presented of program-related investigations conducted by an American aerospace company. The specific objective of Phase I of this program has been to evaluate the impact of the use of broadened properties fuels on combustor design through comprehensive combustor rig testing. Attention is given to combustor concepts, experimental evaluation, results obtained with single stage combustors, the stage combustor concept, and the capability of a variable geometry combustor.
The time resolved flowfield in a low aspect ratio transonic compressor stage has been studied using a high frequency response sphere probe with a bandpass of D.C. to 20 kHz in a blowdown compressor facility. Averaged over the compressor annulus, the data agree well with those measured with standard pitot type probes on the same stage in a conventional test rig. Not all the spanwise distributions agree, however. These differences are explained as errors in the pitot probe readings due to fluctuations in the flow. The experimental data are compared to the results of a three-dimensional inviscid Euler calculation.
Aircraft gas turbine performance and efficiency are related to airfoil tip clearance. The possibility has been considered to obtain optimum performance and efficiency by reducing clearance to a safe minimum with the aid of a closed-loop tip clearance control system, which utilizes a tip clearance sensor. The use of optical sensing methods appears to represent a potential solution to the tip clearance measurement problem. Principles of sensor operation are discussed along with dimensional considerations and diffraction limitations. A description is presented of the study of the feasibility of a certain sensor, taking into account the test rig system, the optical components, and the mounting tube. Attention is also given to the operation of the feasibility-study sensor, performance estimations, the optical fiber bundle, light beam refraction, and aspects of aircraft engine implementation.
Better aerodynamics and ventilation increases fuel efficiency and decreases shipping losses. Trailer is ventilated and cooled by inlet ports in front of rig and outlet ports in middle and rear. Rounded cab and fairing reduce drag by creating an attached airflow.
Analyses and the design, fabrication, and testing of an optical tip clearance sensor with intended application in aircraft propulsion control systems are reported. The design of a sensor test rig, evaluation of optical sensor components at elevated temperatures, sensor design principles, sensor test results at room temperature, and estimations of sensor accuracy at temperatures of an aircraft engine environment are discussed. Room temperature testing indicated possible measurement accuracies of less than 12.7 microns (0.5 mils). Ways to improve performance at engine operating temperatures are recommended. The potential of this tip clearance sensor is assessed.