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The dynamic environment must be known to evaluate high pressure oxidizer turbopump inducer fatigue life. This report sets the dynamic design loads for the alternate turbopump inducer as determined by water-flow rig testing. Also, guidelines are given for estimating the dynamic environment for other inducer and impeller applications.
Results of using vibration-based methods to detect gear tooth fatigue cracks are presented. An experimental test rig was used to fail a number of spur gear specimens through bending fatigue. The gear tooth fatigue crack in each test was initiated through a small notch in the fillet area of a tooth on the gear. The primary purpose of these tests was to verify analytical predictions of fatigue crack propagation direction and rate as a function of gear rim thickness. The vibration signal from a total of three tests was monitored and recorded for gear fault detection research. The damage consisted of complete rim fracture on the two thin rim gears and single tooth fracture on the standard full rim test gear. Vibration-based fault detection methods were applied to the vibration signal both on-line and after the tests were completed. The objectives of this effort were to identify methods capable of detecting the fatigue crack and to determine how far in advance of total failure positive detection was given. Results show that the fault detection methods failed to respond to the fatigue crack prior to complete rim fracture in the thin rim gear tests. In the standard full rim gear test all of the methods responded to the fatigue crack in advance of tooth fracture; however, only three of the methods responded to the fatigue crack in the early stages of crack propagation.
This paper presents a technique for quantifying the wear or damage of gear teeth in a transmission system. The procedure developed in this study can be applied as a part of either an onboard machine health-monitoring system or a health diagnostic system used during regular maintenance. As the developed methodology is based on analysis of gearbox vibration under normal operating conditions, no shutdown or special modification of operating parameters is required during the diagnostic process. The process of quantifying the wear or damage of gear teeth requires a set of measured vibration data and a model of the gear mesh dynamics. An optimization problem is formulated to determine the profile of a time-varying mesh stiffness parameter for which the model output approximates the measured data. The resulting stiffness profile is then related to the level of gear tooth wear or damage. The procedure was applied to a data set generated artificially and to another obtained experimentally from a spiral bevel gear test rig. The results demonstrate the utility of the procedure as part of an overall health-monitoring system.
Thin thermal barrier coatings for protecting aircraft turbine section airfoils are examined in this paper. The discussion focuses on those advances that led first to their use for component life extension, and more recently as an integral part of airfoil design. Development has been driven by laboratory rig and furnace testing corroborated by engine testing and engine field experience. The technology has also been supported by performance modeling to demonstrate benefits and life modeling for mission analysis. Factors which have led to the selection of the current state-of-the-art plasma sprayed and physical vapor deposited zirconia-yttria/MCrAlX TBC's are emphasized, as are observations fundamentally related to the their behavior. Current directions in research into thermal barrier coatings and recent progress at NASA are also noted.
An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel engine applications through rig tests, structural analysis modeling, nondestructive evaluation, and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Although much conflicting literature now exists regarding the impact of thermal barrier coatings on engine performance and fuel consumption, the changes in fuel consumption appear to be less than a few percent and can be negative for state-of-the-art diesel engines. The ability of the thermal barrier coating to improve fuel economy tends to be dependent on a number of factors including the fuel injection system, combustion chamber design, and the initial engine fuel economy. Limited investigations on state-of-the-art diesel engines have indicated that the surface connected porosity and coating surface roughness may influence engine fuel economy. Current research efforts on thermal barrier coatings are primarily directed at reducing in-cylinder heat rejection, thermal fatigue protection of underlying metal surfaces and a possible reduction in diesel engine emissions. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components.
A small scale ground effect test rig was used to study the ground plane flow field generated by a STOVL aircraft in hover. The objective of the research was to support NASA-Ames Research Center planning for the Large Scale Powered Model (LSPM) test for the ARPA-sponsored ASTOVL program. Specifically, small scale oil flow visualization studies were conducted to make a relative assessment of the aerodynamic interference of a proposed strut configuration and a wall configuration on the ground plane stagnation line. A simplified flat plate model representative of a generic jet-powered STOVL aircraft was used to simulate the LSPM. Cold air jets were used to simulate both the lift fan and the twin rear engines. Nozzle Pressure Ratios were used that closely represented those used on the LSPM tests. The flow visualization data clearly identified a shift in the stagnation line location for both the strut and the wall configuration. Considering the experimental uncertainty, it was concluded that either the strut configuration o r the wall configuration caused only a minor aerodynamic interference.
The tribology of brush seals is of considerable interest to turbine engine designers because bristle wear continues to limit long term seal performance and life. To provide better materials characterization and foster the development of improved seals, NASA Lewis has developed a brush seal tuft tester. In this test, a 'paintbrush' sample tuft is loaded under constant contact pressure against the outside diameter of a rotating journal. With this configuration a direct measurement of load and friction is made. Accurate wear rate measurements are possible due to the known contact pressure. Previously reported baseline research using this facility showed good data repeatability and wear morphology similar to published seal data. This paper extends and expands the database for candidate brush seal materials. A series of tuft tests were completed to evaluate the performance of five high temperature superalloy wires sliding against plasma sprayed nichrome-bonded chrome carbide. Wire materials were either nickel-chrome or cobalt-chrome based superalloys. Good corroboration of the tuft results with dynamic seal rig tests was observed; giving additional confidence in the tuft test as a screening and development tool.
An experimental and computational investigation of the effect of lift enhancing tabs on a two-element airfoil was conducted. The objective of the study was to develop an understanding of the flow physics associated with lift enhancing tabs on a multi-element airfoil. A NACA 63(sub 2)-215 ModB airfoil with a 30 percent chord Fowler flap was tested in the NASA Ames 7 by 10 foot wind tunnel. Lift enhancing tabs of various heights were tested on both the main element and the flap for a variety of flap riggings. Computations of the flow over the two-element airfoil were performed using the two-dimensional incompressible Navier-Stokes code INS2D-UP. The computer results predict all of the trends in the experimental data quite well. When the flow over the flap upper surface is attached, tabs mounted at the main element trailing edge (cove tabs) produce very little change in lift. At high flap deflections. however, the flow over the flap is separated and cove tabs produce large increases in lift and corresponding reductions in drag by eliminating the separated flow. Cove tabs permit high flap deflection angles to be achieved and reduce the sensitivity of the airfoil lift to the size of the flap gap. Tabs attached to the flap training edge (flap tabs) are effective at increasing lift without significantly increasing drag. A combination of a cove tab and a flap tab increased the airfoil lift coefficient by 11 percent relative to the highest lift tab coefficient achieved by any baseline configuration at an angle of attack of zero percent and the maximum lift coefficient was increased by more than 3 percent. A simple analytic model based on potential flow was developed to provide a more detailed understanding of how lift enhancing tabs work. The tabs were modeled by a point vortex at the training edge. Sensitivity relationships were derived which provide a mathematical basis for explaining the effects of lift enhancing tabs on a multi-element airfoil. Results of the modeling effort indicate that the dominant effects of the tabs on the pressure distribution of each element of the airfoil can be captured with a potential flow model for cases with no flow separation.
Results of an unsteady thin-layer Navier-Stokes simulation of a 0.658-scale V-22 rotor and wing configuration in hover are presented. All geometric components of the flapped-wing and rotor test rig, including rotor blades, are accurately modeled. Rotor motion and rotor/airframe interference effects are simulated directly using moving body overset grid methods. Tiltrotor hover aerodynamics are visualized via unsteady particle trace images. Wing download predictive ability is demonstrated. Simulation results are compared with experimental data.
This thesis covers the design and setup of a laser doppler velocimeter (LDV) system used to take velocity measurements in an annular combustor model. The annular combustor model is of contemporary design using 60 degree flat vane swirlers, producing a strong recirculation zone. Detailed measurements are taken of the swirler inlet air flow and of the downstream enclosed swirling flow. The laser system used is a two color, two component system set up in forward scatter. Detailed are some of the special considerations needed for LDV use in the confined turbulent flow of the combustor model. LDV measurements in a single swirler rig indicated that the flow changes radically in the first duct height. After this, a flow profile is set up and remains constant in shape. The magnitude of the velocities gradually decays due to viscous damping.
A parched elastohydrodynamic rig was used to determine relative bearing lifetimes as a function of cleaning procedures in a series of accelerated tests. Two ODC-free cleaning procedures (super critical CO2 and ultraviolet-ozone) were compared to a CFC-113 control. Bearings (52100 steel) were run in the counter rotating mode (equivalent to 4600 rpm) with a full complement (i.e. no retainer) and a single charge of lubricant (Krytox 143 AC). Test conditions included: an air atmosphere, 445 N load, approx. 1.0 GPa mean Hertz stress. There was approximately a 50% reduction in life with bearings cleaned with UV/ozone and a 70% reduction in life with SFE CO2 when compared to the Freon control. Possible reasons for these decreases in lifetimes are presented.
A DYNamic Turbine Engine Compressor Code (DYNTECC) has been modified to model speed transients from 0-100% of compressor design speed. The impetus for this enhancement was to investigate stage matching and stalling behavior during a start sequence as compared to rotating stall events above ground idle. The model can simulate speed and throttle excursions simultaneously as well as time varying bleed flow schedules. Results of a start simulation are presented and compared to experimental data obtained from an axi-centrifugal turboshaft engine and companion compressor rig. Stage by stage comparisons reveal the front stages to be operating in or near rotating stall through most of the start sequence. The model matches the starting operating line quite well in the forward stages with deviations appearing in the rearward stages near the start bleed. Overall, the performance of the model is very promising and adds significantly to the dynamic simulation capabilities of DYNTECC.
The cyclic, high-temperature deformation behavior of a wrought cobalt-base super-alloy, Haynes 188, is investigated under combined axial and torsional loads. This is accomplished through the examination of hysteresis loops generated from a biaxial fatigue test program. A high-temperature axial, torsional, and combined axial-torsional fatigue database has been generated on Haynes 188 at 760 C. Cyclic loading tests have been conducted on uniform gage section tubular specimens in a servohydraulic axial-torsional test rig. Test control and data acquisition were accomplished with a minicomputer. The fatigue behavior of Haynes 188 at 760 C under axial, torsional, and combined axial-torsional loads and the monotonic and cyclic deformation behaviors under axial and torsional loads have been previously reported. In this paper, the cyclic hardening characteristics and typical hysteresis loops in the axial stress versus axial strain, shear stress ,versus engineering shear strain, axial strain versus engineering shear strain. and axial stress versus shear stress spaces are presented for cyclic in-phase and out-of-phase axial-torsional tests. For in-phase tests, three different values of the proportionality constant lambda (the ratio of engineering shear strain amplitude to axial strain amplitude, are examined, viz. 0.86, 1.73, and 3.46. In the out-of-phase tests, three different values of the phase angle, phi (between the axial and engineering shear strain waveforms), are studied, viz., 30, 60, and 90 degrees with lambda equals 1.73. The cyclic hardening behaviors of all the tests conducted on Haynes 188 at 760 C are evaluated using the von Mises equivalent stress-strain and the maximum shear stress-maximum engineering shear strain (Tresca) curves. Comparisons are also made between the hardening behaviors of cyclic axial, torsional, and combined in-phase (lambda = 1.73 and phi = 0) and out-of-phase (lambda = 1.73 and phi = 90') axial-torsional fatigue tests. These comparisons are accomplished through simple Ramberg-Osgood type stress-strain functions for cyclic, axial stress-strain and shear stress-engineering shear strain curves.
This paper reports studies of the performance of low-ice-adhesion coatings by NASA Lewis and BFGoodrich. Studies used impact ice accreted both in the NASA Lewis Icing Research Tunnel (IRT) and in the BFGoodrich Icing Wind Tunnel (IWT) and static ice in a BFGoodrich bench-top parallel-plate shear rig. Early tests at NASA Lewis involved simple qualitative evaluations of the ease of removing impact ice from a surface. Coated surfaces were compared with uncoated ones. Some of the coatings were tested again with static ice at BFGoodrich to obtain quantitative measurements. Later, methods to establish the adhesion force on surfaces subjected to impact ice were explored at Lewis. This paper describes the various test programs and the results of testing some of the coatings looked at over the past 5 years. None of the coatings were found to be truly ice-phobic; however, the most effective coatings were found to reduce the adhesion of ice to about 1/2 that of an uncoated aluminum sample.
The effective use of active magnetic bearings for vibration control in turbomachinery depends on an understanding of the forces available from a magnetic bearing actuator. The purpose of this project was to characterize the forces as functions shaft position. Both numerical and experimental studies were done to determine the characteristics of the forces exerted on a stationary shaft by a magnetic bearing actuator. The numerical studies were based on finite element computations and included both linear and nonlinear magnetization functions. Measurements of the force versus position of a nonrotating shaft were made using two separate measurement rigs, one based on strain gage measurement of forces, the other based on deflections of a calibrated beam. The general trends of the measured principal forces agree with the predictions of the theory while the magnitudes of forces are somewhat smaller than those predicted. Other aspects of theory are not confirmed by the measurements. The measured forces in the normal direction are larger than those predicted by theory when the rotor has a normal eccentricity. Over the ranges of position examined, the data indicate an approximately linear relationship between the normal eccentricity of the shaft and the ratio of normal to principal force. The constant of proportionality seems to be larger at lower currents, but for all cases examined its value is between 0.14 and 0.17. The nonlinear theory predicts the existence of normal forces, but has not predicted such a large constant of proportionality for the ratio. The type of coupling illustrated by these measurements would not tend to cause whirl, because the coupling coefficients have the same sign, unlike the case of a fluid film bearing, where the normal stiffness coefficients often have opposite signs. They might, however, tend to cause other self-excited behavior. This possibility must be considered when designing magnetic bearings for flexible rotor applications, such as gas turbines and other turbomachinery.
An experimental and computational investigation of the effect of lift-enhancing tabs on a two-element airfoil has been conducted. The objective of the study was to develop an understanding of the flow physics associated with lift-enhancing tabs on a multi-element airfoil. An NACA 63(2)-215 ModB airfoil with a 30% chord fowler flap was tested in the NASA Ames 7- by 10-Foot Wind Tunnel. Lift-enhancing tabs of various heights were tested on both the main element and the flap for a variety of flap riggings. A combination of tabs located at the main element and flap trailing edges increased the airfoil lift coefficient by 11% relative to the highest lift coefficient achieved by any baseline configuration at an angle of attack of 0 deg, and C(sub 1max) was increased by 3%. Computations of the flow over the two-element airfoil were performed using the two-dimensional incompressible Navier-Stokes code INS2D-UP. The computed results predicted all of the trends observed in the experimental data quite well. In addition, a simple analytic model based on potential flow was developed to provide a more detailed understanding of how lift-enhancing tabs work. The tabs were modeled by a point vortex at the air-foil or flap trailing edge. Sensitivity relationships were derived which provide a mathematical basis for explaining the effects of lift-enhancing tabs on a multi-element airfoil. Results of the modeling effort indicate that the dominant effects of the tabs on the pressure distribution of each element of the airfoil can be captured with a potential flow model for cases with no flow separation.
New high-lift components have been designed for a three-element advanced high-lift research airfoil using a state-of-the-art computational method. The new components were designed with the aim to provide high maximum-lift values while maintaining attached flow on the single-segment flap at approach conditions. This three-element airfoil has been tested in the NASA Langley Low-Turbulence Pressure Tunnel at chord Reynolds number up to 16 million. The performance of the NASA research airfoil is compared to a reference advanced high-lift research airfoil. Effects of Reynolds number on slat and flap rigging have been studied experimentally. The performance trend of this new high-lift design is comparable to that predicted by the computational method over much of the angle of attack range. Nevertheless, the method did not accurately predict the airfoil performance or the configuration-based trends near maximum lift.
This project concerns the design, fabrication and testing of carbon regenerators for use in Stirling power convertors. Radial fiber design with nonmetallic components offers a number of potential advantages over conventional steel regenerators: reduced conduction and pressure drop losses, and the capability for higher temperature, higher frequency operation. Diverse composite fabrication methods are explored and lessons learned are summarized. A pulsed single-blow test rig has been developed that has been used for generating thermal effectiveness data for different flow velocities. Carbon regenerators have been fabricated by carbon vapor infiltration of electroflocked preforms. Performance data in a small Stirling engine are obtained. Prototype regenerators designed for the BP-1000 power convertor were fabricated and delivered to NASA-Lewis.