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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 1,351 records · Page 75

Environmental Barrier Coatings for Silicon-Based Ceramics

Silicon-based ceramics, such as SiC fiber-reinforced SiC (SiC/SiC ceramic matrix composites (CMC) and monolithic silicon nitride (Si3N4), are prime candidates for hot section structural components of next generation gas turbine engines. Silicon-based ceramics, however, suffer from rapid surface recession in combustion environments due to volatilization of the silica scale via reaction with water vapor, a major product of combustion. Therefore, application of silicon-based ceramic components in the hot section of advanced gas turbine engines requires development of a reliable method to protect the ceramic from environmental attack. An external environmental barrier coating (EBC) is considered a logical approach to achieve protection and CP long-term stability. The first generation EBC consisted of two layers, mullite (3Al2O3-2SiO2) bond coat and yttria-stabilized zirconia (YSZ, ZrO2-8 Wt.% Y2O3) top coat. Second generation EBCs, with substantially improved performance compared with the first generation EBC, were developed in the NASA High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program. The first generation EBC consisted of two layers, mullite (3Al2O3-2SiO2) bond coat and yttria-stabilized zirconia (YSZ, ZrO2-8 wt.% Y2O3) top coat. Second generation EBCs, with substantially improved performance compared with the first generation EBC, were developed in the NASA High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program (5). They consist of three layers, a silicon first bond coat, a mullite or a mullite + BSAS (BaO(1-x)-SrO(x)-Al2O3-2SiO2) second bond coat, and a BSAS top coat. The EPM EBCs were applied on SiC/SiC CMC combustor liners in three Solar Turbines (San Diego, CA) Centaur 50s gas turbine engines. The combined operation of the three engines has accumulated over 24,000 hours without failure (approximately 1,250 C maximum combustor liner temperature), with the engine in Texaco, Bakersfield, CA, accumulating about 14,000 hours. As the commercialization of Si-based ceramic components in gas turbines is on the horizon, a major emphasis is placed on EBCs for two reasons. First, they are absolute necessity for the protection of Si-based ceramics from water vapor. Second, they can enable a major enhancement in the performance of gas turbines by creating temperature gradients with the incorporation of a low thermal conductivity layer. Thorough understanding of current state-of-the-art EBCs will provide the foundation upon which development of future EBCs will be based. Phase stability and thermal conductivity of EPM EBCs are published elsewhere. This paper will discuss the chemical/environmental durability and silica volatility of EPM EBCs and their impact on the coating's upper temperature limit.

Lee, Kang N.↗

Rocket Engine Oscillation Diagnostics

Rocket engine oscillating data can reveal many physical phenomena ranging from unsteady flow and acoustics to rotordynamics and structural dynamics. Because of this, engine diagnostics based on oscillation data should employ both signal analysis and physical modeling. This paper describes an approach to rocket engine oscillation diagnostics, types of problems encountered, and example problems solved. Determination of design guidelines and environments (or loads) from oscillating phenomena is required during initial stages of rocket engine design, while the additional tasks of health monitoring, incipient failure detection, and anomaly diagnostics occur during engine development and operation. Oscillations in rocket engines are typically related to flow driven acoustics, flow excited structures, or rotational forces. Additional sources of oscillatory energy are combustion and cavitation. Included in the example problems is a sampling of signal analysis tools employed in diagnostics. The rocket engine hardware includes combustion devices, valves, turbopumps, and ducts. Simple models of an oscillating fluid system or structure can be constructed to estimate pertinent dynamic parameters governing the unsteady behavior of engine systems or components. In the example problems it is shown that simple physical modeling when combined with signal analysis can be successfully employed to diagnose complex rocket engine oscillatory phenomena.

Nesman, Tom↗

NASA's Vision for Jet Noise Engineering

Until recently, the design of jet engines for quiet operation was limited by engineers' ability to predict the jet noise generated by a nozzle exhaust system. More importantly, the 'intermediate steps' between nozzle design and noise had not been understood, limiting the design process to small variations around existing solutions. In recent years NASA's Quiet Aircraft Technology (QAT) Program has advanced the understanding and modeling of jet noise to give engineers the tools they need to design quiet nozzle systems for subsonic exhaust systems. The presentation discusses the approach followed for QAT and argues that a similar effort aimed at supersonic jet exhaust systems will be needed to allow designs of quiet military aircraft in the future.

Kinzie, Kevin W.↗

Optical Measurements at the Combustor Exit of the HIFiRE 2 Ground Test Engine

The development of optical techniques capable of measuring in-stream flow properties of air breathing hypersonic engines is a goal of the Aerospace Propulsion Division at AFRL. Of particular interest are techniques such as tunable diode laser absorption spectroscopy that can be implemented in both ground and flight test efforts. We recently executed a measurement campaign at the exit of the combustor of the HIFiRE 2 ground test engine during Phase II operation of the engine. Data was collected in anticipation of similar data sets to be collected during the flight experiment. The ground test optical data provides a means to evaluate signal processing algorithms particularly those associated with limited line of sight tomography. Equally important, this in-stream data was collected to compliment data acquired with surface-mounted instrumentation and the accompanying flowpath modeling efforts-both CFD and lower order modeling. Here we discuss the specifics of hardware and data collection along with a coarse-grained look at the acquired data and our approach to processing and analyzing it.

Brown, Michael S.↗

Status report - DARPA/NASA convertible turbofan/turboshaft engine program

A development status report is presented for the NASA/Defense Advanced Research Projects Agency convertible turbofan-turboshaft engine, which can power a high speed rotorcraft in vertical flight, as well as in horizontal flight up to speeds of Mach 0.85. The basis for this development program is a modified TF34-GE-400 engine. Program objectives include both the demonstration of dual output mode (jet thrust and shaft horsepower) capability and the development of a control system which will operate the engine in either mode and convert operation between the modes.

Bellin, A. I.↗

Success Path Method: Conformance with Safety Management Systems

All industrial facilities deal with safety hazards such as equipment failures, chemical and toxic releases, and fires and explosions just to name a few. A disciplined framework for managing the integrity of operating systems and processes that handle hazardous substances by applying good design principles, engineering, and operating practices is called process safety. The goal of such framewoks is to prevent the release of energy or material that could cause harm to people or damage to equipment and/or environment. Process safety covers all aspects of facility operation also including design, maintenance, and human and organizational factors that could possibly have effect on process safety. As it will be seen from the discussion below, process safety is just one of the pieces of the much bigger matter, a safety culture. Many industries have long recognized the importance of safety culture in their day-to-day operation. Although the definition of safety culture can slightly differ from organization to organization, in general, a safety culture is how things are done to demonstrate a commitment to safety by everyone involved. An organization acquires safety culture over time as the product of individual and group values, actions, and behaviors toward overall safety. It is important to note that safety culture should not be viewed as some static state that an organization wants to reach. It is more like a constantly evolving level of “how things are done when nobody is watching.” Safety culture is an inherent characteristic of an organization, it is always present, but the level can range on a continuum from undesirable to desirable or more commonly used, from negative to positive. An example for an undesirable, negative safety culture would be a company in which accidents resulting in harm (physical and/or emotional) of its employees, equipment or surrounding environment and community occur frequently. At the other end of the spectrum would be a company in which such accidents are rare or do not occur at all (desired or positive safety culture). Every company/industry exists somewhere within this spectrum.

42 ENGINEERING↗

Space Shuttle Main Engine Off-Nominal Low Power Level Operation

This paper describes Rocketdyne's successful analysis and demonstration of the Space Shuttle Main Engine (SSME) operation at off-nominal power levels during Reusable Launch Vehicle (RLV) evaluation tests. The nominal power level range for the SSME is from 65% rated power level (RPL) to 109% RPL. Off-nominal power levels incrementally demonstrated were: 17% RPL, 22% RPL, 27% RPL, 40% RPL, 45% RPL, and 50% RPL. Additional achievements during low power operation included: use of a hydrostatic bearing High Pressure Oxidizer Turbopump (HPOTP), nominal High Pressure Fuel Turbopump (HPFTP) first rotor critical speed operation, combustion stability at low power levels, and refined definition of nozzle flow separation heat loads.

Bradley, Michael↗

Knowledge engineering for temporal dependency networks as operations procedures

This paper presents a case study of the knowledge engineering process employed to support the Link Monitor and Control Operator Assistant (LMCOA). The LMCOA is a prototype system which automates the configuration, calibration, test, and operation (referred to as precalibration) of the communications, data processing, metric data, antenna, and other equipment used to support space-ground communications with deep space spacecraft in NASA's Deep Space Network (DSN). The primary knowledge base in the LMCOA is the Temporal Dependency Network (TDN), a directed graph which provides a procedural representation of the precalibration operation. The TDN incorporates precedence, temporal, and state constraints and uses several supporting knowledge bases and data bases. The paper provides a brief background on the DSN, and describes the evolution of the TDN and supporting knowledge bases, the process used for knowledge engineering, and an analysis of the successes and problems of the knowledge engineering effort.

Fayyad, Kristina E.↗

Space shuttle orbit maneuvering engine reusable thrust chamber: Adverse operating conditions test report

Test hardware, facilities, and procedures are described along with results of electrically heated tube and channel tests conducted to determine adverse operating condition limits for convectively cooled chambers typical of Space Shuttle Orbit Manuevering Engine designs. Hot-start tests were conducted with corrosion resistant steel and nickel tubes with both monomethylhydrazine and 50-50 coolants. Helium ingestion, in both bubble and froth form, was studied in tubular test sections. Helium bubble ingestion and burn-out limits in rectangular channels were also investigated.

Tobin, R. D.↗

An improved plating process

An alternative to the immersion process for the electrodeposition of chromium from aqueous solutions on the inside diameter (ID) of long tubes is described. The Vessel Plating Process eliminates the need for deep processing tanks, large volumes of solutions, and associated safety and environmental concerns. Vessel Plating allows the process to be monitored and controlled by computer thus increasing reliability, flexibility and quality. Elimination of the trivalent chromium accumulation normally associated with ID plating is intrinsic to the Vessel Plating Process. The construction and operation of a prototype Vessel Plating Facility with emphasis on materials of construction, engineered and operational safety and a unique system for rinse water recovery are described.

Askew, John C.↗

Bioculture System Validation

The Bioculture System first flight will be to validate the performance of the hardware and its automated and manual operational capabilities in the space flight environment of the International Space Station. Biology, Engineering, and Operations tests will be conducted in the Bioculture System fully characterize its automated and manual functions to support cell culturing for short and long durations. No hypothesis-driven research will be conducted with biological sample, and the science leads have all provided their concurrence that none of the data they collect will be considered as proprietary and can be free distributed to the science community. The outcome of the validation flight will be to commission the hardware for use by the science community. This presentation will provide non-proprietary details about the Bioculture System and information about the activities for the first flight.

Bioculture↗

Catalog of Apollo experiment operations

This catalog reviews Apollo mission reports, preliminary science reports, technical crew debriefings, lunar surface operations plans, and various relevant lunar experiment documents, collecting engineering- and operation-specific information by experiment. It is organized by discrete experimental and equipment items emplaced or operated on the lunar surface or at zero gravity during the Apollo missions. It also attempts to summarize some of the general problems encountered on the surface and provides guidelines for the design of future lunar surface experiments with an eye toward operations. Many of the problems dealt with on the lunar surface originated from just a few novel conditions that manifested themselves in various nasty ways. Low gravity caused cables to stick up and get caught on feet, and also made it easy for instruments to tip over. Dust was a problem and caused abrasion, visibility, and thermal control difficulties. Operating in a pressure suit limited a person's activity, especially in the hands. I hope to capture with this document some of the lessons learned from the Apollo era to make the jobs of future astronauts, principle investigators, engineers, and operators of lunar experiments more productive.

Sullivan, Thomas A.↗

Advanced Health Management Algorithms for Crew Exploration Applications

Achieving the goals of the President's Vision for Exploration will require new and innovative ways to achieve reliability increases of key systems and sub-systems. The most prominent approach used in current systems is to maintain hardware redundancy. This imposes constraints to the system and utilizes weight that could be used for payload for extended lunar, Martian, or other deep space missions. A technique to improve reliability while reducing the system weight and constraints is through the use of an Advanced Health Management System (AHMS). This system contains diagnostic algorithms and decision logic to mitigate or minimize the impact of system anomalies on propulsion system performance throughout the powered flight regime. The purposes of the AHMS are to increase the probability of successfully placing the vehicle into the intended orbit (Earth, Lunar, or Martian escape trajectory), increase the probability of being able to safely execute an abort after it has developed anomalous performance during launch or ascent phases of the mission, and to minimize or mitigate anomalies during the cruise portion of the mission. This is accomplished by improving the knowledge of the state of the propulsion system operation at any given turbomachinery vibration protection logic and an overall system analysis algorithm that utilizes an underlying physical model and a wide array of engine system operational parameters to detect and mitigate predefined engine anomalies. These algorithms are generic enough to be utilized on any propulsion system yet can be easily tailored to each application by changing input data and engine specific parameters. The key to the advancement of such a system is the verification of the algorithms. These algorithms will be validated through the use of a database of nominal and anomalous performance from a large propulsion system where data exists for catastrophic and noncatastrophic propulsion sytem failures.

Davidson, Matt↗

Self-teaching digital-computer program for fail-operational control of a turbojet engine in a sea-level test stand

The design and evaluation are described of a digital turbojet engine control which is capable of sensing catastrophic failures in either the engine rotor speed or the compressor discharge static-pressure signal and is capable of switching control modes to maintain near normal operation. The control program was developed for and tested on a turbojet engine located in a sea-level test stand. The control program is also capable of acquiring all the data that are necessary for the fail-operational control to function.

Wallhagen, R. E.↗