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At least 109 records · Page 6

Some composite bearing and seal materials for gas turbine applications: A review

A review is made of the selection and tribological testing of materials for high-temperature bearings and seals. The goal is to achieve good tribological properties over a wide range of temperatures because bearings and seals must be functional from low temperature start-up conditions on up to the maximum temperatures encountered during engine operation. Plasma sprayed composite coatings with favorable tribological properties from 25 to 900 C are discussed. The performance of these coatings in simple tribological bench tests is described. Examples are also given of their performance in high-speed sliding contact seals and as Stirling cylinder liner materials, and as back up lubricants for compliant foil gas bearings.

Sliney, Harold E.↗

Some composite bearing and seal materials for gas turbine applications - A review

A review is made of the selection and tribological testing of materials for high-temperature bearings and seals. The goal is to achieve good tribological properties over a wide range of temperatures because bearings and seals must be functional from low temperature start-up conditions on up to the maximum temperatures encountered during engine operation. Plasma sprayed composite coatings with favorable tribological properties from 25 to 900 C are discussed. The performance of these coatings in simple tribological bench tests is described. Examples are also given of their performance in high-speed sliding contact seals and as Stirling cylinder liner materials, and as backup lubricants for compliant foil gas bearings.

Sliney, Harold E.↗

Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines

As part of a NASA program to reduce fuel consumption of current commercial aircraft engines, methods were investigated for improving the durability of plasma sprayed ceramic coatings for use on vane platforms in the JT9D turbofan engine. Increased durability concepts under evaluation include use of improved strain tolerant microstructures and control of the substrate temperature during coating application. Initial burner rig tests conducted at temperatures of 1010 C (1850 F) indicate that improvements in cyclic life greater than 20:1 over previous ceramic coating systems were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 100-cycle JT9D engine endurance test with only minor damage occurring to the coatings.

Sumner, I. E.↗

Instabilities in uranium plasma and the gas-core nuclear rocket engine

The nonlinear evolution of unstable sound waves in a uranium plasma has been calculated using a multiple time-scale asymptotic expansion scheme. The fluid equations used include the fission power density, radiation diffusion, and the effects of the changing degree of ionization of the uranium atoms. The nonlinear growth of unstable waves is shown to be limited by mode coupling to shorter wavelength waves which are damped by radiation diffusion. This mechanism limits the wave pressure fluctuations to values of order delta P/P approximates 0.00001 in the plasma of a typical gas-core nuclear rocket engine. The instability is thus not expected to present a control problem for this engine.

Tidman, D. A.↗

Near Discharge Cathode Assembly Plasma Potential Measurements in a 30-cm NSTAR Type Ion Engine During Beam Extraction

Floating emissive probe plasma potential data are presented over a two-dimensional array of locations in the near Discharge Cathode Assembly (DCA) region of a 30-cm diameter ring-cusp ion thruster. Discharge plasma data are presented with beam extraction at throttling conditions comparable to the NASA TH Levels 8, 12, and 15. The operating conditions of the Extended Life Test (ELT) of the Deep Space One (DS1) flight spare ion engine, where anomalous discharge keeper erosion occurred, were TH 8 and TH 12 consequently they are of specific interest in investigating discharge keeper erosion phenomena. The data do not validate the presence of a potential hill plasma structure downstream of the DCA, which has been proposed as a possible erosion mechanism. The data are comparable in magnitude to data taken by other researchers in ring-cusp electron-bombardment ion thrusters. The plasma potential structures are insensitive to thruster throttling level with a minimum as low as 14 V measured at the DCA exit plane and increasing gradually in the axial direction. A sharp increase in plasma potential to the bulk discharge value of 26 to 28 volts, roughly 10 mm radially from DCA centerline, was observed. Plasma potential measurements indicate a low-potential plume structure that is roughly 20 mm in diameter emanating from the discharge cathode that may be attributed to a free-standing plasma double layer.

Herman, Daniel A.↗

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗

Computational Model Tracking Primary Electrons, Secondary Electrons, and Ions in the Discharge Chamber of an Ion Engine

Computational modeling of the plasma located in the discharge chamber of an ion engine is an important activity so that the development and design of the next generation of ion engines may be enhanced. In this work a computational tool called XOOPIC is used to model the primary electrons, secondary electrons, and ions inside the discharge chamber. The details of this computational tool are discussed in this paper. Preliminary results from XOOPIC are presented. The results presented include particle number density distributions for the primary electrons, the secondary electrons, and the ions. In addition the total number of a particular particle in the discharge chamber as a function of time, electric potential maps and magnetic field maps are presented. A primary electron number density plot from PRIMA is given in this paper so that the results of XOOPIC can be compared to it. PRIMA is a computer code that the present investigators have used in much of their previous work that provides results that compare well to experimental results. PRIMA only models the primary electrons in the discharge chamber. Modeling ions and secondary electrons, as well as the primary electrons, will greatly increase our ability to predict different characteristics of the plasma discharge used in an ion engine.

Mahalingam, Sudhakar↗

Starter circuit for an ion engine

A starter circuit particularly suitable for a plasma of an ion engine for a spacecraft includes a power supply having an output inductor with a tap. A switch is coupled to the tap. The switch has a control input. A pulse control logic circuit is coupled to said control input, said pulse control logic circuit controlling said switch to an off state to generate a high voltage discharge.

Cardwell, Jr., Gilbert I.↗

Starter circuit for an ion engine

A starter circuit particularly suitable for a plasma of an ion engine for a spacecraft includes a power supply having an output inductor with a tap. A switch is coupled to the tap. The switch has a control input. A pulse control logic circuit is coupled to said control input, said pulse control logic circuit controlling said switch to an off state to generate a high voltage discharge.

Cardwell, Jr., Gilbert I.↗

DBD Plasma Actuators for Flow Control in Air Vehicles and Jet Engines - Simulation of Flight Conditions in Test Chambers by Density Matching

Dielectric Barrier Discharge (DBD) Plasma actuators for active flow control in aircraft and jet engines need to be tested in the laboratory to characterize their performance at flight operating conditions. DBD plasma actuators generate a wall-jet electronically by creating weakly ionized plasma, therefore their performance is affected by gas discharge properties, which, in turn, depend on the pressure and temperature at the actuator placement location. Characterization of actuators is initially performed in a laboratory chamber without external flow. The pressure and temperature at the actuator flight operation conditions need to be simultaneously set in the chamber. A simplified approach is desired. It is assumed that the plasma discharge depends only on the gas density, while other temperature effects are assumed to be negligible. Therefore, tests can be performed at room temperature with chamber pressure set to yield the same density as in operating flight conditions. The needed chamber pressures are shown for altitude flight of an air vehicle and for jet engines at sea-level takeoff and altitude cruise conditions. Atmospheric flight conditions are calculated from standard atmosphere with and without shock waves. The engine data was obtained from four generic engine models; 300-, 150-, and 50-passenger (PAX) aircraft engines, and a military jet-fighter engine. The static and total pressure, temperature, and density distributions along the engine were calculated for sea-level takeoff and for altitude cruise conditions. The corresponding chamber pressures needed to test the actuators were calculated. The results show that, to simulate engine component flows at in-flight conditions, plasma actuator should be tested over a wide range of pressures. For the four model engines the range is from 12.4 to 0.03 atm, depending on the placement of the actuator in the engine. For example, if a DBD plasma actuator is to be placed at the compressor exit of a 300 PAX engine, it has to be tested at 12.4 atm for takeoff, and 6 atm for cruise conditions. If it is to be placed at the low-pressure turbine, it has to be tested at 0.5 and 0.2 atm, respectively. These results have implications for the feasibility and design of DBD plasma actuators for jet engine flow control applications. In addition, the distributions of unit Reynolds number, Mach number, and velocity along the engine are provided. The engine models are non-proprietary and this information can be used for evaluation of other types of actuators and for other purposes.

Ashpis, David E.↗

Ceramic Coatings for Engine Parts

In manufacturing concept, dense, nonporous ceramic coatings applied to metal parts by plasma spraying. Coatings improve resistance of parts to corrosion and erosion in turbines and other engines. Plasma spraying faster and cheaper than previously used method, vapor deposition, and used on large parts as well as small ones.

Schroeder, J. E.↗

Modification of spacecraft potentials by plasma emission

The ion engine operations on Applied Technology Satellite 6 (ATS-6) altered the charge state of the spacecraft, changing the spacecraft surface potentials with respect to the distant plasmas. Plasma emission in quiet environments (plasma temperatures below 1 keV) caused the spacecraft potential to shift from a few volts positive to a few volts negative. A net ion current is emitted in such cases. The emission of a plasma or beam in energetic environments (plasma temperatures in the 5-10-keV range) in sunlight caused larger changes. Typical equilibrium potentials for ATS-6 in such environments were on the order of a hundred volts negative, with variations in potential across the spacecraft surface of comparable magnitude. Engine operations under such conditions raised the mainframe potential to near zero volts, and discharged the differential potentials on the dielectric surfaces. Plasma emission by the plasma bridge was an effective method of discharging kilovolt potentials in eclipse.

Olsen, R. C.↗

Multiring probe in a flowing ionospheric plasma.

Description of a multiring probe placed in an ionospheric flow simulation chamber utilizing a modified Kaufman ion engine for its plasma source. The pertinent details of the probe design, instrumentation, and operating procedures are discussed, and the preliminary results obtained are presented.

Sheldon, J. W.↗