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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,171 records · Page 65

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NASA NTRS1985

Development of thermomechanical life prediction models for thermal barrier coatings

Thermal barrier coatings (TBCs) for turbine airfoils in high-performance engines represent an advanced materials technology with both performance and durability benefits. The foremost TBC benefit is the reduction of heat transferred into air-cooled components. To achieve these benefits, however, the TBC system must be reliable. Mechanistic thermomechanical and thermochemical life models and statistically significant design data are therefore required for the reliable exploitation of TBC benefits on gas turbine airfoils. Garrett's NASA-HOST Program (NAS3-23945) is designed to fulfill these requirements. This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant TBC systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) applied oxidation resistant NiCrAlY bond coating, and an air-plasma-sprayed yttria partially stabilized zirconia insulated layer is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron beam-physical vapor deposition process by Temescal. Thermomechanical life models are being tailored to predict TBC strain tolerance in terms of materials, engine, and mission parameters. Continuum and fracture mechanics approaches and statistical methods are being evaluated to develop tensile and compressive strain functions required to drive a mission analysis capable thermomechanical life model for TBCs. Results of initial testing to calibrate these life models will be presented.

Strangman, T. E.↗

NASA NTRS1985

Thermal barrier coatings for the space shuttle main engine turbine blades

The Space Shuttle Main Engine (SSME) turbopump turbine blades experience extremely severe thermal shocks during start-up and shut-down. For instance, the high pressure fuel turbopump turbine which burns liquid hydrogen operates at approximately 1500 F, but is shut down fuel rich with turbine blades quenced in liquid hydrogen. This thermal shock is a major contributor to blade cracking. The same thermal shock cause the protective ZrO2 thermal barrier coatings to spall or flake off, leaving only the NiCrAlY bond coating which provides only a minimum thermal protection. The turbine blades are therefore life limited to about 3000 sec for want of a good thermal barrier. A suitable thermal barrier coating (TBC) is being developed for the SSME turbine blades. Various TBCs developed for the gas turbine engines were tested in a specially built turbine blade tester. This tester subjects the coated blades to thermal and pressure cycles similar to those during actual operation of the turbine. The coatings were applied using a plasma spraying techniques both under atmospheric conditions and in vacuum. Results are presented. In general vacuum plasma sprayed coatings performed much better than those sprayed under atmospheric conditions. A 50 to 50 blend of Cr2O3 and NiCrAlY, vacuum plasma sprayed on SSME turbopump turbine blades appear to provide significant improvements in coating durability and thermal protection.

Bhat, B. N.↗

NASA NTRS1985

Strain isolated ceramic coatings

Plasma sprayed ceramic coatings are used in gas turbine engines to improve component temperature capability and cooling air efficiency. A compliant metal fiber strain isolator between a plasma sprayed ceramic coating and a metal substrate improves ceramic durability while allowing thicker coatings for better insulation. Development of strain isolated coatings has concentrated on design and fabrication of coatings and coating evaluation via thermal shock testing. In thermal shock testing, five types of failure are possible: buckling failure im compression on heat up, bimetal type failure, isothermal expansion mismatch failure, mudflat cracking during cool down, and long term fatigue. A primary failure mode for thermally cycled coatings is designated bimetal type failure. Bimetal failure is tensile failure in the ceramic near the ceramic-metal interface. One of the significant benefits of the strain isolator is an insulating layer protecting the metal substrate from heat deformation and thereby preventing bimetal type failure.

Tolokan, R. P.↗

NASA NTRS1988

Gear optimization

The use of formal numerical optimization methods for the design of gears is investigated. To achieve this, computer codes were developed for the analysis of spur gears and spiral bevel gears. These codes calculate the life, dynamic load, bending strength, surface durability, gear weight and size, and various geometric parameters. It is necessary to calculate all such important responses because they all represent competing requirements in the design process. The codes developed here were written in subroutine form and coupled to the COPES/ADS general purpose optimization program. This code allows the user to define the optimization problem at the time of program execution. Typical design variables include face width, number of teeth and diametral pitch. The user is free to choose any calculated response as the design objective to minimize or maximize and may impose lower and upper bounds on any calculated responses. Typical examples include life maximization with limits on dynamic load, stress, weight, etc. or minimization of weight subject to limits on life, dynamic load, etc. The research codes were written in modular form for easy expansion and so that they could be combined to create a multiple reduction optimization capability in future.

Vanderplaats, G. N.↗

NASA NTRS1989

Heat flux measurements

A new automated, computer controlled heat flux measurement facility is described. Continuous transient and steady-state surface heat flux values varying from about 0.3 to 6 MW/sq m over a temperature range of 100 to 1200 K can be obtained in the facility. An application of this facility is the development of heat flux gauges for continuous fast transient surface heat flux measurement on turbine blades operating in space shuttle main engine turbopumps. The facility is useful for durability testing at fast temperature transients.

Liebert, Curt H.↗

NASA NTRS1985

Damage tolerant composite wing panels for transport aircraft

Commercial aircraft advanced composite wing surface panels were tested for durability and damage tolerance. The wing of a fuel-efficient, 200-passenger airplane for 1990 delivery was sized using grahite-epoxy materials. The damage tolerance program was structured to allow a systematic progression from material evaluations to the optimized large panel verification tests. The program included coupon testing to evaluate toughened material systems, static and fatigue tests of compression coupons with varying amounts of impact damage, element tests of three-stiffener panels to evaluate upper wing panel design concepts, and the wing structure damage environment was studied. A series of technology demonstration tests of large compression panels is performed. A repair investigation is included in the final large panel test.

Smith, Peter J.↗

NASA NTRS1988

A lunar construction shack vehicle: Final design

A lunar construction shack vehicle is a critical component in most of the plans proposed for the construction of a permanent base on the moon. The Selene Engineering Company (SEC) has developed a concept for this vehicle which is both innovative and practical. The design makes use of the most advanced technology available to meet the goals for a safe, versatile and durable habitat that will serve as a starting point for the initial phase of the construction of a permanent lunar base. This document outlines SEC's proposed design for a lander vehicle which will be fully self-sufficient and will provide for all necessary life support, including consumables and radiation protection, needed by the construction crew until they can complete the assembly of a more permanent habitat. Since it is highly likely that it will take more than one crew to complete the construction of a permanent lunar base, the design emphasis is on systems which can be easily maintained and resupplied and which will take a minimum of start up preparation by succeeding crews.

Source record↗

NASA NTRS1987

Creep fatigue life prediction for engine hot section materials (ISOTROPIC) fifth year progress review

The need for advanced life prediction methods for hot section components for gas turbine engines is becoming more and more evident. The complex local strain and temperature histories at critical locations must be accurately interpreted to account for the effects of various damage mechanisms and their possible interactions. This program is designed to investigate these fundamental damage processes, identify modeling strategies, and develop practical models which can be used to guide the early design and development of new engines and to increase the durability of existing engines.

Nelson, Richard S.↗

NASA NTRS1989

Advanced high temperature instrument for hot section research applications

Programs to develop research instrumentation for use in turbine engine hot sections are described. These programs were initiated to provide improved measurements capability as support for a multidisciplinary effort to establish technology leading to improved hot section durability. Specific measurement systems described here include heat flux sensors, a dynamic gas temperature measuring systems, laser anemometry for hot section applications, an optical system for viewing the interior of a combustor during operation. Thin film sensors for surface temperature and strain measurements, and high temperature strain measuring systems. The paper will describe the state of development of these sensors and measuring systems and, i n some cases, will show examples of measurements made with this instrumentation. The paper covers work done a t the NASA Lewis Research Center and at various contract and grant facilities.

D R Englund↗

NASA NTRS1989

Assessment, development, and application of combustor aerothermal models

The gas turbine combustion system design and development effort is an engineering exercise to obtain an acceptable solution to the conflicting design trade-offs between: combustion efficiency, gaseous emissions, smoke, ignition, restart, lean blowout, burner exit temperature quality, structural durability, and life cycle cost. For many years, these combustor design trade-offs have been carried out with the help of fundamental reasoning and extensive component and bench testing, backed by empirical and experience correlations. Recent advances in the capability of computational fluid dynamics (CFD) codes have led to their application to complex three-dimensional flows such as those in the gas turbine combustor. A number of U.S. Govern- ment and industry sponsored programs have made significant contributions to the formulation, development, and verification of an analytical combustor design methodology which will better define the aerothermal loads in a combustor, and be a valuable tool for design of future combustion systems. The contributions made by NASA Hot Section Technology (HOST) sponsored Aero- thermal Modeling and supporting programs are described in this paper

J D Holdeman↗

NASA NTRS1989

Views on the impact of HOST

The Hot Section Technology (HOST) Project, which was initiated by NASA Lewis Research Center in 1980 and concluded in 1987, was aimed at improving advanced aircraft engine hot section durability through better technical understanding and more accurate design analysis capability. The project was a multidisciplinary, multiorganizational, focused research effort that involved 21 organizations and 70 research and technology activities and generated approximately 250 research reports. No major hardware was developed. To evaluate whether HOST had a significant impact on the overall aircraft engine industry in the development of new engines, interviews were conducted with 41 participants in the project to obtain their views. The summarized results of these interviews are presented. Emphasis is placed on results relative to three-dimensional inelastic structural analysis, thermomechanical fatigue testing, constitutive modeling, combustor aerothermal modeling, turbine heat transfer, protective coatings, computer codes, improved engine design capability, reduced engine development costs, and the impacts on technology transfer and the industry-government partnership.

J B Esgar↗

NASA NTRS1989

A perspective on future directions in aerospace propulsion system simulation

The design and development of aircraft engines is a lengthy and costly process using today's methodology. This is due, in large measure, to the fact that present methods rely heavily on experimental testing to verify the operability, performance, and structural integrity of components and systems. The potential exists for achieving significant speedups in the propulsion development process through increased use of computational techniques for simulation, analysis, and optimization. This paper outlines the concept and technology requirements for a Numerical Propulsion Simulation System (NPSS) that would provide capabilities to do interactive, multidisciplinary simulations of complete propulsion systems. By combining high performance computing hardware and software with state-of-the-art propulsion system models, the NPSS will permit the rapid calculation, assessment, and optimization of subcomponent, component, and system performance, durability, reliability and weight-before committing to building hardware.

Miller, Brent A.↗

NASA NTRS1989

Vacuum plasma spray coating

Currently, protective plasma spray coatings are applied to space shuttle main engine turbine blades of high-performance nickel alloys by an air plasma spray process. Originally, a ceramic coating of yttria-stabilized zirconia (ZrO2.12Y2O3) was applied for thermal protection, but was removed because of severe spalling. In vacuum plasma spray coating, plasma coatings of nickel-chromium-aluminum-yttrium (NiCrAlY) are applied in a reduced atmosphere of argon/helium. These enhanced coatings showed no spalling after 40 MSFC burner rig thermal shock cycles between 927 C (1700 F) and -253 C (-423 F), while current coatings spalled during 5 to 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2.8Y2O3 to the turbine blades of first-stage high-pressure fuel turbopumps utilizing the enhanced NiCrAlY bond-coating process. NiCrAlY bond coating is applied first, with ZrO2.8Y2O3 added sequentially in increasing amounts until a thermal barrier coating is obtained. The enchanced thermal barrier coating has successfully passed 40 burner rig thermal shock cycles.

Holmes, Richard R.↗

NASA NTRS1989

Atomic oxygen effects on materials

Understanding of the basic processes of atomic oxygen interaction is currently at a very elementary level. However, measurement of erosion yields, surface morphology, and optical properties for low fluences have brought about much progress in the past decade. Understanding the mechanisms and those factors that are important for proper simulation of low Earth orbit is at a much lower level of understanding. The ability to use laboratory simulations with confidence to quantifiably address the functional performance and durability of materials in low Earth orbit will be necessary to assure long-term survivability to the natural space environment.

Banks, Bruce A.↗

NASA NTRS1989

Undercutting of defects in thin film protective coatings on polymer surfaces exposed to atomic oxygen

Protection for polymeric surfaces is needed to make them durable in the low Earth orbital environment, where oxidation by atomic oxygen is the predominant failure mechanism. Thin film coatings of oxides such as silicon dioxide are viable candidates to provide this protection, but concern has been voiced over the ability of these coatings to protect when defects are present in the coating due to surface anomalies occurring during the deposition process, handling, or micrometeoroid and debris bombardment in low Earth orbit. When a defected coating protecting a polymer substrate is exposed to atomic oxygen, the defect provides a pathway to the underlying polymer allowing oxidation and subsequent undercutting to occur. Defect undercutting was studied for sputter deposited coatings of silicon dioxide on polyimide Kapton. Preliminary results indicate that undercutting may be limited as long as the coating remains intact with the substrate. Therefore, coatings may not need to be defect free to give protection to the underlying surface.

Rutledge, Sharon K.↗

NASA NTRS1989

Probabilistic structural analysis methods of hot engine structures

Development of probabilistic structural analysis methods for hot engine structures at Lewis Research Center is presented. Three elements of the research program are: (1) composite load spectra methodology; (2) probabilistic structural analysis methodology; and (3) probabilistic structural analysis application. Recent progress includes: (1) quantification of the effects of uncertainties for several variables on high pressure fuel turbopump (HPFT) turbine blade temperature, pressure, and torque of the space shuttle main engine (SSME); (2) the evaluation of the cumulative distribution function for various structural response variables based on assumed uncertainties in primitive structural variables; and (3) evaluation of the failure probability. Collectively, the results demonstrate that the structural durability of hot engine structural components can be effectively evaluated in a formal probabilistic/reliability framework.

Chamis, C. C.↗

NASA NTRS1989

A program for advancing the technology of space concentrators

In 1985, the NASA Lewis Research Center formed a project, the Advanced Solar Dynamics Power Systems Project, for the purpose of advancing the technology of Solar Dynamic Power Systems for space applications beyond 2000. Since then, technology development activities have been initiated for the major components and subsystems such as the concentrator, heat receiver and engine, and radiator. Described here is a program for developing long lived (10 years or more), lighter weight, and more reflective space solar concentrators than is presently possible. The program is progressing along two parallel paths: one is concentrator concept development and the other is the resolution of those critical technology issues that will lead to durable, highly specular, and lightweight reflector elements. Outlined are the specific objectives, long term goals, approach, planned accomplishments for the future, and the present status of the various program elements.

Naujokas, Gerald J.↗

NASA NTRS1987

Ion-assisted deposition of lanthanide trifluorides for VUV applications

The lanthanide trifluorides show promise as vacuum ultraviolet (VUV) coating materials. The optical properties of single-layer coatings vary with deposition temperature, and with ion-beam energy and current density. The optical constants, stoichiometry, durability, moisture adsorption, and crystallinity are studied for trifluoride films made under a variety of deposition conditions.

Lingg, L. J.↗