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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

An Overview of Long Duration Sodium Heat Pipe Tests

High temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, and Stirling cycle heat sources; with the resurgence of space nuclear power, additional applications include reactor heat removal elements and radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly long-term materials compatibility is being evaluated through the use of high temperature life test heat pipes. Thermacore International, Inc., has carried out several sodium heat pipe life tests to establish long term operating reliability. Four sodium heat pipes have recently demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A 3l6L stainless steel heat pipe with a sintered porous nickel wick structure and an integral brazed cartridge heater has successfully operated at 650 to 700 C for over 115,000 hours without signs of failure. A second 3l6L stainless steel heat pipe with a specially-designed Inconel 60 I rupture disk and a sintered nickel powder wick has demonstrated over 83,000 hours at 600 to 650 C with similar success. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 41 ,000 hours at nearly 700 0c. A hybrid (i.e. gas-fired and solar) heat pipe with a Haynes 230 envelope and a sintered porous nickel wick structure was operated for about 20,000 hours at nearly 700 C without signs of degradation. These life test results collectively have demonstrated the potential for high temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability, Detailed design specifications, operating hi story, and test results are described for each of these sodium heat pipes. Lessons learned and future life test plans are also discussed.

Rosenfeld, John H.↗
NASA NTRS2012

Turbine Engine Disk Rotor Health Monitoring Assessment Using Spin Tests Data

Detecting rotating engine component malfunctions and structural anomalies is increasingly becoming a crucial key feature that will help boost safety and lower maintenance cost. However, achievement of such technology, which can be referred to as a health monitoring remains somewhat challenging to implement. This is mostly due to presence of scattered loading conditions, crack sizes, component geometry and material properties that hinders the simplicity of imposing such application. Different approaches are being considered to assist in developing other means of health monitoring or nondestructive techniques to detect hidden flaws and mini cracks before any catastrophic events occur. These methods extend further to assess material discontinuities and other defects that have matured to the level where a failure is very likely. This paper is focused on presenting data obtained from spin test experiments of a turbine engine like rotor disk and their correlation to the development of a structural health monitoring and fault detection system. The data collected includes blade tip clearance, blade tip timing measurements and shaft displacements. The experimental results are collected at rotational speeds up to 10,000 Rpm and tests are conducted at the NASA Glenn Research Center s Rotordynamics Laboratory via a high precision spin system. Additionally, this study offers a closer glance at a selective online evaluation of a rotating disk using advanced capacitive, microwave and eddy current sensor technology.

Abdul-Aziz, Ali↗
NASA NTRS1990

Failure analysis and modeling of a VAXcluster system

This paper discusses the results of a measurement-based analysis of real error data collected from a DEC VAXcluster multicomputer system. In addition to evaluating basic system dependability characteristics such as error and failure distributions and hazard rates for both individual machines and for the VAXcluster, reward models were developed to analyze the impact of failures on the system as a whole. The results show that more than 46 percent of all failures were due to errors in shared resources. This is despite the fact that these errors have a recovery probability greater than 0.99. The hazard rate calculations show that not only errors, but also failures occur in bursts. Approximately 40 percent of all failures occur in bursts and involved multiple machines. This result indicates that correlated failures are significant. Analysis of rewards shows that software errors have the lowest reward (0.05 vs 0.74 for disk errors). The expected reward rate (reliability measure) of the VAXcluster drops to 0.5 in 18 hours for the 7-out-of-7 model and in 80 days for the 3-out-of-7 model.

Tang, Dong↗
NASA NTRS2004

Applicability of a Crack-Detection System for Use in Rotor Disk Spin Test Experiments Being Evaluated

Engine makers and aviation safety government institutions continue to have a strong interest in monitoring the health of rotating components in aircraft engines to improve safety and to lower maintenance costs. To prevent catastrophic failure (burst) of the engine, they use nondestructive evaluation (NDE) and major overhauls for periodic inspections to discover any cracks that might have formed. The lowest cost fluorescent penetrant inspection NDE technique can fail to disclose cracks that are tightly closed during rest or that are below the surface. The NDE eddy current system is more effective at detecting both crack types, but it requires careful setup and operation and only a small portion of the disk can be practically inspected. So that sensor systems can sustain normal function in a severe environment, health-monitoring systems require the sensor system to transmit a signal if a crack detected in the component is above a predetermined length (but below the length that would lead to failure) and lastly to act neutrally upon the overall performance of the engine system and not interfere with engine maintenance operations. Therefore, more reliable diagnostic tools and high-level techniques for detecting damage and monitoring the health of rotating components are very essential in maintaining engine safety and reliability and in assessing life.

Abdul-Aziz, Ali↗
NASA NTRS1996

Fluctuating Pressure Analysis of a 2-D SSME Nozzle Air Flow Test

To better understand the Space Shuttle Main Engine (SSME) startup/shutdown tansients, an airflow test of a two dimensional nozzle was conducted at Marshall Space Flight Center's trisonic wind tunnel. Photographic and other instrumentation show during an SSME start large nozzle shell distortions occur as the Mach disk is passing through the nozzle. During earlier develop of the SSME, this startup transient resulted in low cycle fatigue failure of one of the LH2 feedlines. The two dimensional SSME nozzle test was designed to measure the static and fluctuating pressure environment and color Schlieren video during the startup and shutdown phases of the run profile.

Reed, Darren↗
NASA NTRS1976

An improved turbine disk design to increase reliability of aircraft jet engines

An analytical study was performed on a novel disk design to replace the existing high-pressure turbine, stage 1 disk on the CF6-50 turbofan engine. Preliminary studies were conducted on seven candidate disk design concepts. An integral multidisk design with bore entry of the turbine blade cooling air was selected as the improved disk design. This disk has the unique feature of being redundant such that if one portion of the disk would fail, the remaining portion would prevent the release of large disk fragments from the turbine system. Low cycle fatigue lives, initial defect propagation lives, burst speed, and the kinetic energies of probable disk fragment configurations were calculated, and comparisons were made with the existing disk, both in its current material, IN 718, and with the substitution of an advanced alloy, Rene 95. The design for redundancy approach which necessitated the addition of approximately 44.5 kg (98 lb) to the design disk substantially improved the life of the disk. The life to crack initiation was increased from 30,000 cycles to more than 100,000 cycles. The cycles to failure from initial defect propagation were increased from 380 cycles to 1564 cycles. Burst speed was increased from 126 percent overspeed to 149 percent overspeed. Additionally, the maximum fragment energies associated with a failure were decreased by an order of magnitude.

Barack, W. N.↗
NASA NTRS1992

A real-time diagnostic and performance monitor for UNIX

There are now over one million UNIX sites and the pace at which new installations are added is steadily increasing. Along with this increase, comes a need to develop simple efficient, effective and adaptable ways of simultaneously collecting real-time diagnostic and performance data. This need exists because distributed systems can give rise to complex failure situations that are often un-identifiable with single-machine diagnostic software. The simultaneous collection of error and performance data is also important for research in failure prediction and error/performance studies. This paper introduces a portable method to concurrently collect real-time diagnostic and performance data on a distributed UNIX system. The combined diagnostic/performance data collection is implemented on a distributed multi-computer system using SUN4's as servers. The approach uses existing UNIX system facilities to gather system dependability information such as error and crash reports. In addition, performance data such as CPU utilization, disk usage, I/O transfer rate and network contention is also collected. In the future, the collected data will be used to identify dependability bottlenecks and to analyze the impact of failures on system performance.

Dong, Hongchao↗
NASA NTRS1994

Microstructurally based variations on the dwell fatgue life of titanium alloy IMI 834

An experimental study was undertaken to determine the role of microstructure on the fatigue life reduction observed in titanium alloy IMI 834 under dwell loading conditions. The wave forms compared were a trapezoid with 15 and 30 second hold times at the maximum test load and a baseline, 10 Hertz, haversine. The stress ratio for both loading wave forms was 0.10. The fatigue loading of each specimen was conducted in a vacuum within a scanning electron microscope chamber which minimized the possibility that the laboratory environment would adversely affect the material behavior. Two microstructural conditions were investigated in the experimental program. The first involved standard 'disk' material with equiaxed alpha in a transformed beta matrix. The second material was cut from the same disk forging as the first but was heat treated to obtain a martensitic alpha prime microstructure. Tensile tests were performed prior to the onset of the fatigue loading portion of the study, and it was determined that the yield strengths of the specimens from both material conditions were within ten percent. The maximum fatigue loads were chosen to be 72 percent of the average yield strength for both materials as determined from the tensile tests. It was found that the cycles to failure from the 10 Hertz loading wave form were reduced by a factor of approximately five when the loading was changed to the trapezoidal wave form for the standard 'disk' material. The fatigue life reduction for the martensitic structure under identical test conditions was approximately 1.75. The improvement observed with the martensitic structure also was accompanied by an increase in overall fatigue life for the wave forms tested. This paper will review the results and conclusions of this effort.

Thomsen, Mark L.↗
NASA NTRS2002

Major Effects of Nonmetallic Inclusions on the Fatigue Life of Disk Superalloy Demonstrated

The fatigue properties of modern powder metallurgy disk alloys can vary because of the different steps of materials and component processing and machining. Among these variables, the effects of nonmetallic inclusions introduced during the powder atomization and handling processes have been shown to significantly degrade low-cycle fatigue life. The levels of inclusion contamination have, therefore, been reduced to less than 1 part per million in state-of-the-art nickel disk powder-processing facilities. Yet the large quantities of compressor and turbine disks weighing from 100 to over 1000 lb have enough total volume and surface area for these rare inclusions to still be present and limit fatigue life. The objective of this study was to investigate the effects on fatigue life of these inclusions, as part of the Crack Resistant Disk Materials task within the Ultra Safe Propulsion Project. Inclusions were carefully introduced at elevated levels in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were then performed on extracted test specimens at 650 C. Analyses were performed to compare the low-cycle fatigue lives and failure initiation sites as functions of inclusion content and fatigue conditions. Powder of the nickel-base superalloy U720 was atomized in argon at Special Metals Corporation, Inc., using production-scale high-cleanliness powder-processing facilities and handling practices. The powder was then passed through a 270-mesh screen. One portion of this powder was set aside for subsequent consolidation without introduced inclusions. Two other portions of this powder were seeded with alumina inclusions. Small, polycrystalline soft (Type 2) inclusions of about 50 mm diameter were carefully prepared and blended into one powder lot, and larger hard (Type 1) inclusions of about 150 mm mean diameter were introduced into the other seeded portion of powder. All three portions of powder were then sealed in separate containers, hot isostatically pressurized, extruded, forged into subscale disks, and heat treated. Low-cycle-fatigue specimens were then extracted, machined, and tested. Fatigue tests were performed at 650 C in closed-loop servohydraulic testing machines using induction heating and axial extensometers. All tests were continued to failure, and fractographic evaluations were performed on all specimens to determine the crack initiation sites. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface, as shown for each type of inclusion in the following bar chart. The inclusions significantly reduced fatigue life from unseeded material levels, as shown in the bar chart. These effects were found to depend on the strain range, strain ratio, and inclusion size. Tests at lower strain ranges and higher strain ratios resulted in larger effects of inclusions on life. Inclusion effects on life were thereby maximized in tests at the lowest strain range of 0.6 percent and the most positive strain ratio of 0.5. Under these conditions, small Type 2 inclusions reduced life substantially-- about 20 times, whereas large Type 1 inclusions dramatically reduced life 100 times. These results clearly demonstrate that it is essential to include the effects of inclusions for realistic predictions of disk fatigue life. Important issues, including temperature dependence, crack initiation versus propagation, surface treatments, realistic disk features and machining, and realistic disk spin testing will be addressed to accurately model inclusion effects on disk fatigue life. Fatigue life varied from well over 105 cycles for no inclusions to a little over 103 cycles for 100-micrometer inclusions. A single crack initiating at a surface-connected seeded inclusion caused failure in each case.

Gabb, Timothy P.↗
NASA NTRS1994

Effects of Mistuning on the Forced Response of Turbomachinery Rotors

The basic purpose of this research has been to develop a fundamental understanding of the effects of blade-to-blade dissimilarities, or mistuning, on the dynamics of nearly cyclic bladed-disk assemblies. This topic is of importance as mistuning has been shown to increase the forced response amplitudes of some blades significantly, and even to lead to blade failure. Furthermore, the current trend toward high performance propulsion turbomachinery designed for finite service life demands an accurate prediction of system performance and dynamics at the design stage. This objective has been achieved by carrying out the following tasks. First, the investigation of the free and forced responses of representative, yet sufficiently simple blade assembly models that capture all the important characteristics of typical turbomachinery rotors. Second, the development of computational methods that predict the effects of mistuning in a systematic and reliable way, along with the development of a systematic reduced-order modeling procedure for mistuned bladed disks. Third, the application of these findings and the tools developed to an industrial rotor, namely the first stage of turbine blades of the oxidizer turbopump in the space shuttle main rocket engine (SSME). The research supported by NASA has led to the development of a coherent theory for mistuned blade assemblies. The further implementation of these computational tools into the forced response prediction system currently under development in the Structural Dynamics Branch-FREPS-would enable the designer and the analyst to: (1) identify types of blade assemblies highly sensitive to mistuning in various frequency and other parameter ranges and (2) characterize mistuning effects on their forced response by predicting true response amplitudes and fatigue life estimates.

Pierre, Christophe↗
NASA NTRS1994

Effects of Mistuning on the Forced Response of Turbomachinery Rotors

The basic purpose of this research has been to develop a fundamental understanding of the effects of blade-to-blade dissimilarities, or mistuning, on the dynamics of nearly cyclic bladed-disk assemblies. This topic is of importance as mistuning has been shown to increase the forced response amplitudes of some blades significantly, and even to lead to blade failure. Furthermore, the current trend toward high performance propulsion turbomachinery designed for finite service life demands an accurate prediction of system performance and dynamics at the design stage. This objective has been achieved by carrying out the following tasks. First, the investigation of the free and forced responses of representative, yet sufficiently simple blade assembly models that capture all the important characteristics of typical turbomachinery rotors. Second, the development of computational methods that predict the effects of mistuning in a systematic and reliable way, along with the development, of a systematic reduced-order modeling procedure for mistuned bladed disks. Third, the application of these findings and the tools developed to an industrial rotor, namely the first stage of turbine blades of the oxidizer turbopump in the space shuttle main rocket engine (SSME). The research supported by NASA has led to the development of a coherent theory for mistuned blade assemblies. The further implementation of these computational tools into the forced response prediction system currently under development in the Structural Dynamics Branch Forced Response Prediction System (FREPS) would enable the designer and the analyst (1) to identify types of blade assemblies highly sensitive to mistuning in various frequency and other parameter ranges and (2), to characterize mistuning effects on their forced response by predicting true response amplitudes and fatigue life estimates.

Stefko, George L.↗
NASA NTRS1989

Recoverable distributed shared virtual memory - Memory coherence and storage structures

This paper examines the problem of implementing rollback recovery in multicomputer distributed shared virtual memory environments, in which the shared memory is implemented in software and exists only virtually. A user-transparent checkpointing recovery scheme and new twin-page disk storage management are presented to implement a recoverable distributed shared virtual memory. The checkpointing scheme is integrated with the shared virtual memory management. The twin-page disk approach allows incremental checkpointing without an explicit undo at the time of recovery. A single consistent checkpoint state is maintained on stable disk storage. The recoverable distributed shared virtual memory allows the system to restart computation from a previous checkpoint due to a processor failure without a global restart.

Wu, Kun-Lung↗
NASA NTRS1974

A new mechanism of failure on polymers

Transparent laminates containing imbedded crystals of various ionic and nonionic substances were prepared and their swelling in distilled water was observed. It was found that under certain conditions, disk-shaped cracks formed around the swollen pockets containing a dissolving crystal. Such cracks can form before equilibrium swelling is reached and may severely damage the elastomer.

Fedors, R. F.↗
NASA NTRS1992

Site partitioning for distributed redundant disk arrays

Distributed redundant disk arrays can be used in a distributed computing system or database system to provide recovery in the presence of temporary and permanent failures of single sites. In this paper, we look at the problem of partitioning the sites into redundant arrays in such way that the communication costs for maintaining the parity information are minimized. We show that the partitioning problem is NP-complete and we propose two heuristic algorithms for finding approximate solutions.

Mourad, Antoine N.↗
NASA NTRS1994

Forced response of mistuned bladed disks

Small mistuning can cause large, catastrophic changes in blade vibrational response whereby the amplitudes of vibration of some blades may increase by several hundred percent. This can produce 'rogue' blades and HCF failure. The free and forced responses may be highly sensitive to mistuning, and the tuned system predictions may be qualitatively in error and grossly underestimate blade forced response and overestimate fatigue life. Manufacturing tolerances, material non-uniformities, nonidentical root fixtures, and in-service degradation result in blade-to-blade differences that destroy cyclic symmetry in bladed discs. Therefore, a credible forced response prediction system for turbomachinery vibration must take mistuning into account. This report addresses these problems, states several objectives, and introduces NASA research program thrusts concerning this problem. This report was given during the NASA LeRC Workshop on Forced Response in Turbomachinery in August of 1993.

Pierre, Christophe↗
NASA NTRS2001

Deformation and Life Analysis of Composite Flywheel Disk and Multi-disk Systems

In this study an attempt is made to put into perspective the problem of a rotating disk, be it a single disk or a number of concentric disks forming a unit. An analytical model capable of performing an elastic stress analysis for single/multiple, annular/solid, anisotropic/isotropic disk systems, subjected to both pressure surface tractions, body forces (in the form of temperature-changes and rotation fields) and interfacial misfits is derived and discussed. Results of an extensive parametric study are presented to clearly define the key design variables and their associated influence. In general the important parameters were identified as misfit, mean radius, thickness, material property and/or load gradation, and speed; all of which must be simultaneously optimized to achieve the "best" and most reliable design. Also, the important issue of defining proper performance/merit indices (based on the specific stored energy), in the presence of multiaxiality and material anisotropy is addressed. These merit indices are then utilized to discuss the difference between flywheels made from PMC and TMC materials with either an annular or solid geometry. Finally two major aspects of failure analysis, that is the static and cyclic limit (burst) speeds are addressed. In the case of static limit loads, upper, lower, and out-of-plane bounds for disks with constant thickness are presented for both the case of internal pressure loading (as one would see in a hydroburst test) and pure rotation (as in the case of a free spinning disk). The results (interaction diagrams) are displayed graphically in designer friendly format. For the case of fatigue, a representative fatigue/life master curve is illustrated in which the normalized limit speed versus number of applied cycles is given for a cladded TMC disk application.

Arnold, S. M.↗
NASA NTRS1960

A Solid Film Lubricant Composition for Use at High Sliding Velocities in Liquid Nitrogen

Solid-lubricant-containing compositions can be of value as films and solid bodies for bearing and seal surfaces in low-temperature liquefied gases. An experimental composition including polytetrafluoroethylene (PTFE), an epoxy resin, and lithium-alumina-silicate was studied in friction, wear, and endurance experiments in liquid nitrogen (−320 F). This composition was formulated to approximate the thermal expansion of metals used in cryogenic systems. Hemisphere (3/6-in. radius) rider specimens were used and in most experiments the load was 1000 g. Films (0.005-in. thick) on disk specimens gave good endurance life, low rider wear, and desirable friction (f = 0.02 to 0.07). They functioned at a higher sliding velocity (no failure at 16, 000 ft/min) with copper rider specimens than with stainless steel riders (failure at 9000 ft/min). Solid rider material of the experimental composition had good friction and wear properties at sliding velocities above 4000 ft/min. It is important to use the experimental composition with mating materials having good thermal conductivity.

Wisander, D. W.↗
NASA NTRS1997

Nonlinear Dynamic Analysis of Disordered Bladed-Disk Assemblies

In a effort to address current needs for efficient, air propulsion systems, we have developed some new analytical predictive tools for understanding and alleviating aircraft engine instabilities which have led to accelerated high cycle fatigue and catastrophic failures of these machines during flight. A frequent cause of failure in Jets engines is excessive resonant vibrations and stall flutter instabilities. The likelihood of these phenomena is reduced when designers employ the analytical models we have developed. These prediction models will ultimately increase the nation's competitiveness in producing high performance Jets engines with enhanced operability, energy economy, and safety. The objectives of our current threads of research in the final year are directed along two lines. First, we want to improve the current state of blade stress and aeromechanical reduced-ordered modeling of high bypass engine fans, Specifically, a new reduced-order iterative redesign tool for passively controlling the mechanical authority of shroudless, wide chord, laminated composite transonic bypass engine fans has been developed. Second, we aim to advance current understanding of aeromechanical feedback control of dynamic flow instabilities in axial flow compressors. A systematic theoretical evaluation of several approaches to aeromechanical feedback control of rotating stall in axial compressors has been conducted. Attached are abstracts of two .papers under preparation for the 1998 ASME Turbo Expo in Stockholm, Sweden sponsored under Grant No. NAG3-1571. Our goals during the final year under Grant No. NAG3-1571 is to enhance NASA's capabilities of forced response of turbomachines (such as NASA FREPS). We with continue our development of the reduced-ordered, three-dimensional component synthesis models for aeromechanical evaluation of integrated bladeddisk assemblies (i.e., the disk, non-identical bladeing etc.). We will complete our development of component systems design optimization strategies for specified vibratory stresses and increased fatigue life prediction of assembly components, and for specified frequency margins on the Campbell diagrams of turbomachines. Finally, we will integrate the developed codes with NASA's turbomachinery aeromechanics prediction capability (such as NASA FREPS).

McGee, Oliver G., III↗