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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Rapid Design and Manufacturing of High-Performance Materials for Turbine Blades

This research demonstrated the concept of carbide precipitation-strengthened refractory high entropy alloys (RHEA). The advantage of a precipitation strengthened alloy is all phases are in thermodynamic equilibrium promoting microstructural stability, and consequently retention of properties at elevated temperatures. Additionally, as with any precipitation strengthened – or age hardened - alloy, components can be heat-treated after manufacturing to manipulate the microstructure and optimize properties for performance. This is an advantage of the precipitation strengthened alloys over composites and ceramics materials, where the microstructure and properties are essentially fixed upon the initial materials manufacturing stage. High throughput (HT), multi-scale computer modeling was used to identifying novel RHEA compositions with desired characteristics needed for precipitation strengthening. Designs were validated by producing small ingots via are melting. The results showed that carbides precipitated and consequently, the strength of the alloys (measured in compression) increased after heat-treatment, which is the desired effect. The project also demonstrated the feasibility of producing articles from RHEA by additive manufacturing (AM). Electron beam melting (EBM) and laser direct energy deposition (L-DED) additive manufacturing methods, were explored with various processing parameters were interrogated for both methods. Sound (crack-free and dense) precipitation strengthened RHEA samples were produced via EDM AM, demonstrating the feasibility of the concept.

36 MATERIALS SCIENCE↗
NASA NTRS1992

CFD analysis of pump 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 Navier-Stokes flow solver, FDNS, embedded with the extended k-epsilon turbulence model and with appropriate moving interface boundary conditions, is developed to analyze turbulent flows in the turbomachinery devices. The FDNS code was benchmarked with its numerical predictions of the pump consortium inducer, and provides satisfactory results. In the present study, a CFD analysis of the pump consortium impeller will be conducted with the application of the FDNS code. The pump consortium impeller, with partial blades, is the new design concept of the advanced rocket engine.

Cheng, Gary C.↗
DOE OSTI2020

Wake Statistics of Different-Scale Wind Turbines under Turbulent Boundary Layer Inflow

Subscale wind turbines can be installed in the field for the development of wind technologies, for which the blade aerodynamics can be designed in a way similar to that of a full-scale wind turbine. However, it is not clear whether the wake of a subscale turbine, which is located closer to the ground and faces different incoming turbulence, is also similar to that of a full-scale wind turbine. In this work we investigate the wakes from a full-scale wind turbine of rotor diameter 80 m and a subscale wind turbine of rotor diameter of 27 m using large-eddy simulation with the turbine blades and nacelle modeled using actuator surface models. The blade aerodynamics of the two turbines are the same. In the simulations, the two turbines also face the same turbulent boundary inflows. The computed results show differences between the two turbines for both velocity deficits and turbine-added turbulence kinetic energy. Such differences are further analyzed by examining the mean kinetic energy equation.

17 WIND ENERGY↗
NASA NTRS1976

Performance of 1.15-pressure-ratio fan stage at several rotor blade setting angles with reverse flow

A 51 cm diameter low pressure ratio fan stage was tested in reverse flow. Survey flow data were taken over the range of rotative speed from 50 percent to 100 percent design speed at several rotor blade setting angles through both flat and feather pitch. Normal flow design values of pressure ratio and weight flow were 1.15 and 29.9 kg/sec with a rotor tip speed of 243.8 m/sec. The maximum thrust in reverse flow was 52.5 percent of design thrust in normal flow.

Kovich, G.↗
NASA NTRS2009

Compressor Study to Meet Large Civil Tilt Rotor Engine Requirements

A vehicle concept study has been made to meet the requirements of the Large Civil Tilt Rotorcraft vehicle mission. A vehicle concept was determined, and a notional turboshaft engine system study was conducted. The engine study defined requirements for the major engine components, including the compressor. The compressor design-point goal was to deliver a pressure ratio of 31:1 at an inlet weight flow of 28.4 lbm/sec. To perform a conceptual design of two potential compressor configurations to meet the design requirement, a mean-line compressor flow analysis and design code were used. The first configuration is an eight-stage axial compressor. Some challenges of the all-axial compressor are the small blade spans of the rear-block stages being 0.28 in., resulting in the last-stage blade tip clearance-to-span ratio of 2.4%. The second configuration is a seven-stage axial compressor, with a centrifugal stage having a 0.28-in. impeller-exit blade span. The compressors conceptual designs helped estimate the flow path dimensions, rotor leading and trailing edge blade angles, flow conditions, and velocity triangles for each stage.

Veres, Joseph P.↗
NASA NTRS2009

Compressor Study to Meet Large Civil Tilt Rotor Engine Requirements

A vehicle concept study has been made to meet the requirements of the Large Civil Tilt Rotorcraft vehicle mission. A vehicle concept was determined, and a notional turboshaft engine system study was conducted. The engine study defined requirements for the major engine components, including the compressor. The compressor design-point goal was to deliver a pressure ratio of 31:1 at an inlet weight flow of 28.4 lbm/sec. To perform a conceptual design of two potential compressor configurations to meet the design requirement, a mean-line compressor flow analysis and design code were used. The first configuration is an eight-stage axial compressor. Some challenges of the all-axial compressor are the small blade spans of the rear-block stages being 0.28 in., resulting in the last-stage blade tip clearance-to-span ratio of 2.4 percent. The second configuration is a seven-stage axial compressor, with a centrifugal stage having a 0.28-in. impeller-exit blade span. The compressors conceptual designs helped estimate the flow path dimensions, rotor leading and trailing edge blade angles, flow conditions, and velocity triangles for each stage.

Veres, Joseph P.↗
NASA NTRS2003

Aerodynamic Design Study of an Advanced Active Twist Rotor

An Advanced Active Twist Rotor (AATR) is currently being developed by the U.S. Army Vehicle Technology Directorate at NASA Langley Research Center. As a part of this effort, an analytical study was conducted to determine the impact of blade geometry on active-twist performance and, based on those findings, propose a candidate aerodynamic design for the AATR. The process began by creating a baseline design which combined the dynamic design of the original Active Twist Rotor and the aerodynamic design of a high lift rotor concept. The baseline model was used to conduct a series of parametric studies to examine the effect of linear blade twist and blade tip sweep, droop, and taper on active-twist performance. Rotor power requirements and hub vibration were also examined at flight conditions ranging from hover to advance ratio = 0.40. A total of 108 candidate designs were analyzed using the second-generation version of the Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics (CAMRAD II) code. The study concluded that the vibration reduction capabilities of a rotor utilizing controlled, strain-induced twisting are enhanced through the incorporation of blade tip sweep, droop, and taper into the blade design, while they are degraded by increasing the nose-down linear blade twist. Based on the analysis of rotor power, hub vibration, and active-twist response, a candidate aerodynamic design for the AATR consisting of a blade with approximately 10 degrees of linear blade twist and a blade tip design with 30 degree sweep, 10 degree droop, and 2.5:1 taper ratio over the outer five percent of the blade is proposed.

Sekula, Martin K.↗
NASA NTRS2005

System Developed for Real-Time Blade-Flutter Monitoring in the Wind Tunnel

A real-time system has been developed to monitor flutter vibrations in turbomachinery. The system is designed for continuous processing of blade tip timing data at a rate of 10 MB/sec. A USB 2.0 interface provides uninterrupted real-time processing of the data, and the blade-tip arrival times are measured with a 50-MHz oscillator and a 24-bit pipelined architecture counter. The input stage includes a glitch catcher, which reduces the probability of detecting a ghost blade to negligible levels. A graphical user interface provides online interrogation of any blade tip from any light probe sensor. Alternatively, data from all blades and all sensors can be superimposed into a single composite scatter plot displaying the vibration amplitude of each blade.

Kurkov, Anatole P.↗
NASA NTRS2009

Lightweight Bulldozer Attachment for Construction and Excavation on the Lunar Surface

A lightweight bulldozer blade prototype has been designed and built to be used as an excavation implement in conjunction with the NASA Chariot lunar mobility platform prototype. The combined system was then used in a variety of field tests in order to characterize structural loads, excavation performance and learn about the operational behavior of lunar excavation in geotechnical lunar simulants. The purpose of this effort was to evaluate the feasibility of lunar excavation for site preparation at a planned NASA lunar outpost. Once the feasibility has been determined then the technology will become available as a candidate element in the NASA Lunar Surface Systems Architecture. In addition to NASA experimental testing of the LANCE blade, NASA engineers completed analytical work on the expected draft forces using classical soil mechanics methods. The Colorado School of Mines (CSM) team utilized finite element analysis (FEA) to study the interaction between the cutting edge of the LANCE blade and the surface of soil. FEA was also used to examine various load cases and their effect on the lightweight structure of the LANCE blade. Overall it has been determined that a lunar bulldozer blade is a viable technology for lunar outpost site preparation, but further work is required to characterize the behavior in 1/6th G and actual lunar regolith in a vacuum lunar environment.

Mueller, Robert↗
DOE OSTI2020

Measurements of the Flow in the Vicinity of an Additively Manufactured Turbine Leading-Edge Using X-Ray Particle Tracking Velocimetry

X-ray particle tracking velocimetry (PTV) is performed, for the first time, to measure the velocity field inside a leading-edge of a turbine blade made by laser-additive-manufacturing (LAM) process. The traditional showerhead holes were replaced by a porous matrix in the leading-edge. The flow through such a leading-edge piece cannot be faithfully recreated by traditional prototype testing methods due to the surface roughness and imperfections caused by LAM process. Hence, direct measurement is the only option. However, it is difficult to measure flow inside such pieces with traditional velocimetry measurements due to the existence of metallic walls. Moreover, small internal size and high flow speeds call for a measurement technique with high spatial and temporal resolutions. To address these issues, we performed time-resolved X-ray PTV using the Advanced Photon Source (APS) synchrotron facility at the Argonne National Laboratory (ANL). A hydraulic system was constructed to run water, mixed with seeding particles, through the leading-edge piece. A high-speed camera captured the images of the seeding particles, which were later processed to create particle tracks. The time-averaged velocity field showed distinct pairs of vortices located in front of the porous outlet inside the leading-edge piece. The inlet channel showed reversed flow due to partial obstruction by the porous inlet of the test piece. Such knowledge of the flow field inside a leading-edge of a turbine blade will help us to design better cooling paths leading to higher cooling efficiency and increased life-span of a turbine blade.

42 ENGINEERING↗
NASA NTRS1995

Testing And Analysis Of Rubbing Of Turbine-Blade Tips

Unique combination of established techniques of experimentation and theoretical analysis devised to study stresses induced in turbine blades by intermittent or periodic rubbing of tips of blades in turbine housings. Rubbing is inevitable consequence of modern high-speed, high-efficiency turbine designs, which call for blade-tip clearances as small as possible. Necessary to quantify stresses caused by rubbing in order to predict fatigue lives of blades. Testing apparatus simulates blade-tip rubbing and measures dynamic responses of blades.

Davis, Gary A.↗
NASA NTRS1988

Structural optimization of rotor blades with integrated dynamics and aerodynamics

The problem of structural optimization of helicopter rotor blades with integrated dynamic and aerodynamic design considerations is addressed. Results of recent optimization work on rotor blades for minimum weight with constraints on multiple coupled natural flap-lag frequencies, blade autorotational inertia and centrifugal stress has been reviewed. A strategy has been defined for the ongoing activities in the integrated dynamic/aerodynamic optimization of rotor blades. As a first step, the integrated dynamic/airload optimization problem has been formulated. To calculate system sensitivity derivatives necessary for the optimization recently developed, Global Sensitivity Equations (GSE) are being investigated. A need for multiple objective functions for the integrated optimization problem has been demonstrated and various techniques for solving the multiple objective function optimization are being investigated. The method called the Global Criteria Approach has been applied to a test problem with the blade in vacuum and the blade weight and the centrifugal stress as the multiple objectives. The results indicate that the method is quite effective in solving optimization problems with conflicting objective functions.

Chattopadhyay, Aditi↗
NASA NTRS1989

Structural optimization of rotor blades with integrated dynamics and aerodynamics

The problem of structural optimization of helicopter rotor blades with integrated dynamic and aerodynamic design considerations is addressed. Results of recent optimization work on rotor blades for minimum weight with constraints on multiple coupled natural flap-lag frequencies, blade autorotational inertia and centrifugal stress has been reviewed. A strategy has been defined for the ongoing activities in the integrated dynamic/aerodynamic optimization of rotor blades. As a first step, the integrated dynamic/airload optimization problem has been formulated. To calculate system sensitivity derivatives necessary for the optimization recently developed, Global Sensitivity Equations (GSE) are being investigated. A need for multiple objective functions for the integrated optimization problem has been demonstrated and various techniques for solving the multiple objective function optimization are being investigated. The method called the Global Criteria Approach has been applied to a test problem with the blade in vacuum and the blade weight and the centrifugal stress as the multiple objectives. The results indicate that the method is quite effective in solving optimization problems with conflicting objective functions.

Chattopadhyay, Aditi↗
NASA NTRS2002

Low-Speed Fan Noise Reduction With Trailing Edge Blowing

An experimental proof-of-concept test was conducted to demonstrate reduction of rotor-stator interaction noise through rotor-trailing edge blowing. The velocity deficit from the viscous wake of the rotor blades was reduced by injecting air into the wake from a trailing edge slot. Composite hollow rotor blades with internal flow passages were designed based on analytical codes modeling the internal flow. The hollow blade with interior guide vanes creates flow channels through which externally supplied air flows from the root of the blade to the trailing edge. The impact of the rotor wake-stator interaction on the acoustics was also predicted analytically. The Active Noise Control Fan, located at the NASA Glenn Research Center, was used as the proof- of-concept test bed. In-duct mode and farfield directivity acoustic data were acquired at blowing rates (defined as mass supplied to trailing edge blowing system divided by fan mass flow) ranging from 0.5 to 2.0 percent. The first three blade passing frequency harmonics at fan rotational speeds of 1700 to 1900 rpm were analyzed. The acoustic tone power levels (PWL) in the inlet and exhaust were reduced 11.5 and -0.1, 7.2 and 11.4, 11.8 and 19.4 PWL dB, respectively. The farfield tone power levels at the first three harmonics were reduced 5.4, 10.6, and 12.4 dB PWL. At selected conditions, two-component hotwire and stator vane unsteady surface pressures were acquired. These measurements illustrate the physics behind the noise reduction.

Sutliff, Daniel L.↗
NASA NTRS2004

Stator Blade Laser Window Research

All turbofan engines used in modern aviation contain a series of fan blades and compressor blades which are all connected to one drive shaft. Inside the jet engine between each set of blades are stator blades, which are pitched opposite of the fan and compressor blades, the stator blades are both rotational and axial fixed in place. The project that I was assigned to involves the QAT 22 fan test rig; which is currently under final design review and very soon will be fabricated. The purpose of this research facility is to better understand the effects of stator blades. Stator blades are used to straiten the air in a turbine. The researcher's primary aim is to determine what the airflow is like at both the leading edge and the trailing edge of a stator blade. My work focused on designing the windows usable for both a compressor rig and a test fan rig. The difference between the two is the test fan application will be looking into a stator blade array rather than just looking at the rotor. My discussion will include a detailed explanation of how the PIV laser window system functions fiom start to finish. I will also discuss how the information is gathered and organized. Further more I plan to talk about the purpose of this kind of research and the advantages to using this technology to determine the airflow characteristics of blade designs. Finally I will discuss the researcher s conclusion on the relationship between aerodynamics of a blade and how noise is produced. NASA's main goal with this particular facility is find ways to quiet engine noise by reducing the amount of cavitations that occurs around the blades of a turbofan engine. Additional information is included in the original extended abstract.

Lugas, Grant A.↗
NASA NTRS2000

A Novel Method for Reducing Rotor Blade-Vortex Interaction

One of the major hindrances to expansion of the rotorcraft market is the high-amplitude noise they produce, especially during low-speed descent, where blade-vortex interactions frequently occur. In an attempt to reduce the noise levels caused by blade-vortex interactions, the flip-tip rotor blade concept was devised. The flip-tip rotor increases the miss distance between the shed vortices and the rotor blades, reducing BVI noise. The distance is increased by rotating an outboard portion of the rotor tip either up or down depending on the flight condition. The proposed plan for the grant consisted of a computational simulation of the rotor aerodynamics and its wake geometry to determine the effectiveness of the concept, coupled with a series of wind tunnel experiments exploring the value of the device and validating the computer model. The computational model did in fact show that the miss distance could be increased, giving a measure of the effectiveness of the flip-tip rotor. However, the wind experiments were not able to be conducted. Increased outside demand for the 7'x lO' wind tunnel at NASA Ames and low priority at Ames for this project forced numerous postponements of the tests, eventually pushing the tests beyond the life of the grant. A design for the rotor blades to be tested in the wind tunnel was completed and an analysis of the strength of the model blades based on predicted loads, including dynamic forces, was done.

Glinka, A. T.↗
NASA NTRS2003

An Experimental and Computational Investigation of Oscillating Airfoil Unsteady Aerodynamics at Large Mean Incidence

A major challenge in the design and development of turbomachine airfoils for gas turbine engines is high cycle fatigue failures due to flutter and aerodynamically induced forced vibrations. In order to predict the aeroelastic response of gas turbine airfoils early in the design phase, accurate unsteady aerodynamic models are required. However, accurate predictions of flutter and forced vibration stress at all operating conditions have remained elusive. The overall objectives of this research program are to develop a transition model suitable for unsteady separated flow and quantify the effects of transition on airfoil steady and unsteady aerodynamics for attached and separated flow using this model. Furthermore, the capability of current state-of-the-art unsteady aerodynamic models to predict the oscillating airfoil response of compressor airfoils over a range of realistic reduced frequencies, Mach numbers, and loading levels will be evaluated through correlation with benchmark data. This comprehensive evaluation will assess the assumptions used in unsteady aerodynamic models. The results of this evaluation can be used to direct improvement of current models and the development of future models. The transition modeling effort will also make strides in improving predictions of steady flow performance of fan and compressor blades at off-design conditions. This report summarizes the progress and results obtained in the first year of this program. These include: installation and verification of the operation of the parallel version of TURBO; the grid generation and initiation of steady flow simulations of the NASA/Pratt&Whitney airfoil at a Mach number of 0.5 and chordal incidence angles of 0 and 10 deg.; and the investigation of the prediction of laminar separation bubbles on a NACA 0012 airfoil.

Capece, Vincent R.↗
NASA NTRS1976

Single-stage experimental evaluation of low aspect ratio, highly loaded blading for compressors. Part 9: Stage F and stage G, volume 1

Two single-stage, 0.77 hub/tip ratio axial-flow compressors were tested to evaluate the effectiveness of low aspect ratio blading as a means of obtaining higher stage loadings. One compressor, designated Stage F, was comprised of circular arc blading with an aspect ratio of 0.9 for both the rotor and stator. This compressor was tested with uniform inlet flow, hub radial, tip radial, and 180 deg arc circumferential inlet distortion. The second compressor, designated Stage G, was comprised of multiple circular arc blading with an aspect ratio of 1.0 for both the rotor and stator. This compressor was tested with uniform inlet flow only. Design rotor tip speeds for Rotor F and Rotor G were 285 m/sec (934 ft/sec) and 327 m/sec (1,074 ft/sec) respectively. Both stages operated at high loading levels with adequate efficiency and operating range. The peak efficiencies and corresponding average stage diffusion factors for Stages F and G at design rotor speed were 86.4% and 84.1% and 0.59 and 0.55 respectively. The surge margin at peak efficiency for Stage F was 12.6% and the corresponding value for Stage G was 16.5%. Both stages experienced a loss in efficiency with increasing rotor speed; however, the multiple circular arc rotor delayed the characteristic loss in efficiency within increasing Mach number to higher Mach number.

Cheatham, J. G.↗