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At least 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

SSME HPFTP/AT Turbine Blade Platform Featherseal Damper Design

During the Space Shuttle Main Engines (SSM) HPFtP/AT development program, engine hot fire testing resulted in turbine blade fatigue cracks. The cracks were noted after only a few tests and a several hundred seconds versus the design goal of 60 tests and >30,000 seconds. Subsequent investigation attributed the distress to excessive steady and dynamic loads. To address these excessive turbine blade loads, Pratt & Whitney Liquid Space Propulsion engineers designed and developed retrofitable turbine blade to blade platform featherseal dampers. Since incorporation of these dampers, along with other turbine blade system improvements, there has been no observed SSME HPFTP/AT turbine blade fatigue cracking. The high time HPFTP/AT blade now has accumulated 32 starts and 19,200 seconds hot fire test time. Figure #1 illustrates the HPFTP/AT turbine blade platform featherseal dampers. The approached selected was to improve the turbine blade structural capability while simultaneously reducing loads. To achieve this goal, the featherseal dampers were designed to seal the blade to blade platform gap and damp the dynamic motions. Sealing improves the steady stress margins by increasing turbine efficiency and improving turbine blade attachment thermal conditioning. Load reduction was achieved through damping. Thin Haynes 188 sheet metal was selected based on its material properties (hydrogen resistance, elongation, tensile strengths, etc.). The 36,000 rpm wheel speed of the rotor result in a normal load of 120#/blade. The featherseals then act as micro-slip dampers during actual SSME operation. After initial design and analysis (prior to full engine testing), the featherseal dampers were tested in P&W's spin rig facility in West Palm Beach, Florida. Both dynamic strain gages and turbine blade tip displacement measurements were utilized to quantify the featherseal damper effectiveness. Full speed (36,000 rpm), room temperature rig testing verified the elimination of fundamental mode (i.e, modes 1 & 2) resonant response. The reduction in turbine blade dynamic response is shown for a typical turbine blade. This paper discusses the design and verification of these dampers. The numerous benefits associated with this design concept warrants consideration in existing and future turbomachinery applications.

Montgomery, S. K.↗
NASA NTRS1999

Overview of Current Turbine Aerodynamic Analysis and Testing at MSFC

An overview of the current turbine aerodynamic analysis and testing activities at NASA/Marshall Space Flight Center (MSFC) is presented. The presentation is divided into three areas. The first area is the three-dimensional (3D), unsteady Computational Fluid Dynamics (CFD) analysis of the Fastrac turbine. Results from a coupled nozzle, blade, and exit guide vane analysis and from an uncoupled nozzle and coupled blade and exit guide vane will be presented. Unsteady pressure distributions, frequencies, and exit profiles from each analysis will be compared and contrasted. The second area is the testing and analysis of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) turbine with instrumented first stage blades. The SSME HPFTP turbine was tested in air at the MSFC Turbine Test Equipment (TTE). Pressure transducers were mounted on the first stage blades. Unsteady, 3D CFD analysis was performed for this geometry and flow conditions. A sampling of the results will be shown. The third area is a status of the Turbine Performance Optimization task. The objective of this task is to improve the efficiency of a turbine for potential use on a next generation launch vehicle. This task includes global optimization for the preliminary design, detailed optimization for blade shapes and spacing, and application of advanced CFD analysis. The final design will be tested in the MSFC TTE.

Griffin, Lisa W.↗
NASA NTRS2000

A Study of Single Crystal Fatigue Failure Criteria

This paper presents the results of a study whose objective was to study the applicability of different failure equations in modeling low cycle fatigue (LCF) test data for single crystal test specimens. A total of four failure criteria were considered in this study. One of the failure equations was developed by Pratt & Whitney and is based on normal and shear strains on the primary crystallographic slip planes of the single crystal material. Other failure equations considered are based on isotropic criteria. Because these failure equations were originally developed for isotropic materials such as structural steel, they were modified to be applicable to the single crystal slip systems of the LCF specimen material. By observing how closely the various equations were able to reduce the scatter in the LCF test data, the applicability of those equations in modeling the LCF test data was assessed. It is desired to subsequently use the failure equation with the highest correlation in the development of a new single crystal failure criterion for the Alternative Turbopump Development (ATD) for the space shuttle main engine (SSME) High Pressure Fuel Turbopump (HPFTP).

Sayyah, Tarek↗
NASA NTRS1988

STS-26 Preflight Press Briefing: Shuttle Systems Changes (2)

This NASA KSC video release presents part of a press conference held prior to Discovery flight STS-26, the first shuttle mission flown following the 51-L Challenger accident. The video includes presentations by Gerald Smith (Solid Rocket Booster (SRB) Project Manager) and Joe Lombardo (Space Shuttle Main Engine (SSME) Project Manager) discussing the major changes that were made to the SRB and SSME between 51-L and STS-26. Mr. Smith's talk centered on the changes and redesigns made to the solid rocket motor field joint, the case to nozzle joint, the SRB aft skirt, and the ET aft attach ring. Mr. Lombardo discusses test data evaluation, SSME inspections and the SSME heat exchanger in particular.

Source record↗
NASA NTRS2000

Effect of Crystal Orientation on Analysis of Single-Crystal, Nickel-Based Turbine Blade Superalloys

High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.

Swanson, G. R.↗
NASA NTRS2000

Marshall Space Flight Center High Speed Turbopump Bearing Test Rig

The Marshall Space Flight Center has a unique test rig that is used to test and develop rolling element bearings used in high-speed cryogenic turbopumps. The tester is unique in that it uses liquid hydrogen as the coolant for the bearings. This test rig can simulate speeds and loads experienced in the Space Shuttle Main Engine turbopumps. With internal modifications, the tester can be used for evaluating fluid film, hydrostatic, and foil bearing designs. At the present time, the test rig is configured to run two ball bearings or a ball and roller bearing, both with a hydrostatic bearing. The rig is being used to evaluate the lifetimes of hybrid bearings with silicon nitride rolling elements and steel races.

Gibson, Howard↗
NASA NTRS2000

Laser Brazing of High Temperature Braze Alloy

The Space Shuttle Main Engine (SSME) consists of 1080 conical tubes, which are furnace brazed themselves, manifolds, and surrounding structural jacket making almost four miles of braze joints. Subsequent furnace braze cycles are performed due to localized braze voids between the coolant tubes. SSME nozzle experiences extremely high heat flux (180 mW/sq m) during hot fire. Braze voids between coolant tubes may result in hot combustion gas escape causing jacket bulges. The nozzle can be disqualified for flight or result in mission failure if the braze voids exceed the limits. Localized braze processes were considered to eliminate braze voids, however, damage to the parent materials often prohibited use of such process. Being the only manned flight reusable rocket engine, it has stringent requirement on the braze process. Poor braze quality or damage to the parent materials limits the nozzle service life. The objective of this study was to develop a laser brazing process to provide quality, localized braze joints without adverse affect on the parent materials. Gold (Au-Cu-Ni-Pd-Mn) based high temperature braze alloys were used in both powder and wire form. Thin section iron base superalloy A286 tube was used as substrate materials. Different Laser Systems including CO2 (10.6 micrometers, 1kW), ND:YAG (1.06 micrometers, 4kW). and direct diode laser (808nm. 150W) were investigated for brazing process. The laser process variables including wavelength. laser power, travel speed and angle of inclination were optimized according to bead geometry and braze alloy wetting at minimum heat input level, The properties of laser brazing were compared to that of furnace brazing. Microhardness profiles were used for braze joint property comparison between laser and furnace brazing. The cooling rate of laser brazing was compared to furnace brazing based on secondary dendritic arm spacing, Both optical and Scanning Electron Microscope (SEM) were used to evaluate the microstructures of the braze materials and tube substrate. Metallography of the laser braze joint was compared to the furnace braze. SEM Energy Disperse X-Ray Spectra (EDX) and back scattered imaging were used to analyze braze alloy segregation. Although all of the laser systems, CO2, ND:YAG, and direct diode laser produced good braze joint, the direct diode laser was selected for its system simplicity, compactness and portability. Excellent laser and braze alloy coupling is observed with powder alloy compared to braze alloy wire. Good wetting is found with different gold based braze alloys. The laser brazing process can be optimized so that the adverse affect on the parent materials can be eliminated. Metallography of the laser braze joint has shown that quality braze joint was produced with laser brazing process. Penetration of the laser braze to the substrate is at neglectable level. Zero penetration is observed. Microstructure examinations shown that no observable changes of the microstructure (grain structure and precipitation) in the HAZ area between laser braze and furnace braze. Wide gaps can be laser brazed with single pass for up to 0.024 inches. Finer dendritic structure is observed in laser brazing compared with equiaxial and coarser grain of the furnace brazing microstructure. Greater segregation is also found in the furnace braze. Higher hardness of the laser braze joint comparing to furnace braze is observed due to the fast cooling rate and Finer microstructure in the laser brazing. Laser braze joint properties meet or exceed the furnace joint properties. Direct diode laser for thin section tube brazing with high temperature braze alloys have been successfully demonstrated. The laser's high energy density and precise control has shown significant advantages in reducing process heat input to the substrates and provide high quality braze joints comparing to other localized braze process such as torch, TIG, and MPTA processes. Significant cost savings can be realized particularly with localized braze comparing to a full furnace braze cycle.

Gao, Y. P.↗
NASA NTRS2000

Vacuum Plasma Spray of CuCrNb Alloy for Advanced Liquid - Fuel Combustion Chambers

The copper-8 atomic percent chromium-4 atomic percent niobium (CuCrNb) alloy was developed by Glenn Research Center (formally Lewis Research Center) as an improved alloy for combustion chamber liners. In comparison to NARloy-Z, the baseline (as in Space Shuttle Main Engine) alloy for such liners, CuCrNb demonstrates mechanical and thermophysical properties equivalent to NARloy-Z, but at temperatures 100 C to 150 C (180 F to 270 F) higher. Anticipated materials related benefits include decreasing the thrust cell liner weight 5% to 20%, increasing the service life at least two fold over current combustion chamber design, and increasing the safety margins available to designers. By adding an oxidation and thermal barrier coating to the liner, the combustion chamber can operate at even higher temperatures. For all these benefits, however, this alloy cannot be formed using conventional casting and forging methods because of the levels of chromium and niobium, which exceed their solubility limit in copper. Until recently, the only forming process that maintains the required microstructure of CrNb intermetallics is powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. Vacuum plasma spray (VPS) has been demonstrated as a method to form structural articles including small combustion chambers from the CuCrNb alloy. In addition, an oxidation and thermal barrier layer can be formed integrally on the hot wall of the liner that improve performance and extend service life. This paper discusses the metallurgy and thermomechanical properties of VPS formed CuCrNb versus the baseline powder metallurgy process, and the manufacturing of small combustion chamber liners at Marshall Space Flight Center using the VPS process. The benefits to advanced propulsion initiatives of using VPS to fabricate combustion chamber liners while maintaining the superior CuCrNb properties are also presented.

Zimmerman, Frank↗
NASA NTRS1999

Space Shuttle Orbital Maneuvering Subsystem (OMS) Engine Propellant Leakage Ball-Valve Shaft Seals

Evidence of propellant leakage across ball-valve shaft seals has been noted during the disassembly of five flight engines and one test engine at the NASA Lyndon B. Johnson Space Center, White Sands Test Facility. Based on data collected during the disassembly of these five engines, the consequences of propellant leakage across the ball-valve shaft seals can be divided into four primary areas of concern: Damage to the ball-valve pinion shafts, damage to sleeved bearings inside the ball-valve and actuator assemblies, degradation of the synthetic rubber o-rings used in the actuator assemblies, and corrosion and degradation to the interior of the actuator assemblies. The exact time at which leakage across the ball-valve shaft seals occurs has not been determined, however, the leakage most likely occurs during engine firings when, depending on the specification used, ball-valve cavity pressures range as high as 453 to 550 psia. This potential pressure range for the ball-valve cavities greatly exceeds the acceptance leakage test pressure of 332 psia. Since redesign and replacement of the ball-valve shaft seals is unlikely, the near term solution to prevent damage that occurs from shaft-seal leakage is to implement a routine overhaul and maintenance program for engines in the fleet. Recommended repair, verification, and possible preventative maintenance measures are discussed in the paper.

Lueders, Kathy↗
NASA NTRS2000

Demonstration of the Application of Composite Load Spectra (CLS) and Probabilistic Structural Analysis (PSAM) Codes to SSME Heat Exchanger Turnaround Vane

This report describes a probabilistic structural analysis performed to determine the probabilistic structural response under fluctuating random pressure loads for the Space Shuttle Main Engine (SSME) turnaround vane. It uses a newly developed frequency and distance dependent correlation model that has features to model the decay phenomena along the flow and across the flow with the capability to introduce a phase delay. The analytical results are compared using two computer codes SAFER (Spectral Analysis of Finite Element Responses) and NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) and with experimentally observed strain gage data. The computer code NESSUS with an interface to a sub set of Composite Load Spectra (CLS) code is used for the probabilistic analysis. A Fatigue code was used to calculate fatigue damage due to the random pressure excitation. The random variables modeled include engine system primitive variables that influence the operating conditions, convection velocity coefficient, stress concentration factor, structural damping, and thickness of the inner and outer vanes. The need for an appropriate correlation model in addition to magnitude of the PSD is emphasized. The study demonstrates that correlation characteristics even under random pressure loads are capable of causing resonance like effects for some modes. The study identifies the important variables that contribute to structural alternate stress response and drive the fatigue damage for the new design. Since the alternate stress for the new redesign is less than the endurance limit for the material, the damage due high cycle fatigue is negligible.

Rajagopal, Kadambi R.↗
NASA NTRS2000

Space Shuttle Propulsion Safety Upgrades

This document is a viewgraph presentation which reviews the proposed upgrades to the Space Shuttle Propulsion system, to improve safety, and reduce significant hazards. The goals of the program are to reduce the risk of a catastrophe in ascent, to achieve significant reduction in orbital and entry systems, and to improve the crew cockpit situational awareness for managing the critical operational situations. The document reviews the upgrades to the propulsion system which are planned to improve the safety. These include modifications to the Advanced Thrust Vector Control, modifications to the Space Shuttle Main Engine Block III, improvement in the Advanced Health Management System, the use of Friction Stir welding on the external tank, which is expected to improve mechanical properties, and reduce defect rate, and the modification of the propellant grains geometry.

Humphries, William Randy, Jr.↗
NASA NTRS2000

NASA and Youth in the 21st Century

This document is several slides from a presentation: (1) shows the space shuttle main engine (SSME), and the characteristics; (2) shows models of the SSME High pressure Fuel Turbopump (HPFTP) Alternate Turbopump Design (ATD); (4) shows the X34, (5) a test firing of the Fast Trac Engine;(6) shows a thermal analysis for the housing and the Rotor. Several pictures do not have captions.

Roman, Jose↗
NASA NTRS2000

SSME Advanced Health Management: Project Overview

This document is the viewgraphs from a presentation concerning the development of the Health Management system for the Space Shuttle Main Engine (SSME). It reviews the historical background of the SSME Advanced Health Management effort through the present final Health management configuration. The document includes reviews of three subsystems to the Advanced Health Management System: (1) the Real-Time Vibration Monitor System, (2) the Linear Engine Model, and (3) the Optical Plume Anomaly Detection system.

Plowden, John↗
NASA NTRS2000

Unsteady Phenomena During Operation of the SSME Fuel Flowmeter

This report describes a part of the analysis carried in support of the SSME (Space Shuttle Main Engine) Fuel Flowmeter redesign, addressing an intensely researched phenomenon known as "shifting" of the flowmeter constant value. It consists of a sudden change in the flowmeter indication, which occurs simultaneously with the onset of an oscillatory variation of the rotor speed. The change in the flowmeter indications does not correspond to a real change in the volumetric flow through the device. Several causes have been investigated in detail, in the past, without conclusive evidence towards a cause of this phenomenon. The present analysis addresses the flow physics through the flowmeter by assembling results from 3-D CFD (computational fluid dynamics) calculations, airfoil C(sub D)/C(sub L) performance curves and mass moment of inertia characteristics of the rotor into a synergistic calculation which simulates the unsteady regime of the flowmeter operation. The results show that the 4-bladed rotor interacts with the periodic flow pattern created behind the flow straightener upstream in a manner that generates a steady, periodic fluctuation in the rotor's speed. The amplitude of this fluctuation is significantly smaller than the 0.5% of mean speed threshold which constitutes a flight operational limit. When manufacturing errors occur, however, the fluctuations are amplified and can generate a significant apparent change in the flowmeter indication. Two types of possible fabrication errors-which can occur even for parts fabricated within the accepted tolerances for the blade airfoil-are presented, together with their effect on the flowmeter operation.

Marcu, Bogdan↗
NASA NTRS2001

High-Speed Observer: Automated Streak Detection in SSME Plumes

A high frame rate digital video camera installed on test stands at Stennis Space Center has been used to capture images of Space Shuttle main engine plumes during test. These plume images are processed in real time to detect and differentiate anomalous plume events occurring during a time interval on the order of 5 msec. Such speed yields near instantaneous availability of information concerning the state of the hardware. This information can be monitored by the test conductor or by other computer systems, such as the integrated health monitoring system processors, for possible test shutdown before occurrence of a catastrophic engine failure.

Rieckoff, T. J.↗
NASA NTRS2001

Probabilistic Structural Analysis and Reliability Using NESSUS With Implemented Material Strength Degradation Model

This project included both research and education objectives. The goal of this project was to advance innovative research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction for improved reliability and safety of structural components of aerospace and aircraft propulsion systems. Research and education partners included Glenn Research Center (GRC) and Southwest Research Institute (SwRI) along with the University of Texas at San Antonio (UTSA). SwRI enhanced the NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) code and provided consulting support for NESSUS-related activities at UTSA. NASA funding supported three undergraduate students, two graduate students, a summer course instructor and the Principal Investigator. Matching funds from UTSA provided for the purchase of additional equipment for the enhancement of the Advanced Interactive Computational SGI Lab established during the first year of this Partnership Award to conduct the probabilistic finite element summer courses. The research portion of this report presents the cumulation of work performed through the use of the probabilistic finite element program, NESSUS, Numerical Evaluation and Structures Under Stress, and an embedded Material Strength Degradation (MSD) model. Probabilistic structural analysis provided for quantification of uncertainties associated with the design, thus enabling increased system performance and reliability. The structure examined was a Space Shuttle Main Engine (SSME) fuel turbopump blade. The blade material analyzed was Inconel 718, since the MSD model was previously calibrated for this material. Reliability analysis encompassing the effects of high temperature and high cycle fatigue, yielded a reliability value of 0.99978 using a fully correlated random field for the blade thickness. The reliability did not change significantly for a change in distribution type except for a change in distribution from Gaussian to Weibull for the centrifugal load. The sensitivity factors determined to be most dominant were the centrifugal loading and the initial strength of the material. These two sensitivity factors were influenced most by a change in distribution type from Gaussian to Weibull. The education portion of this report describes short-term and long-term educational objectives. Such objectives serve to integrate research and education components of this project resulting in opportunities for ethnic minority students, principally Hispanic. The primary vehicle to facilitate such integration was the teaching of two probabilistic finite element method courses to undergraduate engineering students in the summers of 1998 and 1999.

Bast, Callie C.↗
NASA NTRS2001

Evaluation Of The NASA Quality Surveillance System Pilot In Meeting Requirements For Contractor Surveillance Under Performance Based Contracting

The use of performance-based contracting at Kennedy Space Center has necessitated a shift from intrusive oversight of contractor activities to an insight surveillance role. This paper describes the results of a pilot implementation of the NASA Quality Surveillance System (NQSS) in the Space Shuttle Main Engines Processing Facility. The NQSS is a system to sample contractor activities using documented procedures, specifications, drawings and observations of work in progress to answer the question "Is the contractor doing what they said they would do?" The concepts of the NQSS are shown to be effective in providing assurance of contractor quality. Many of the concepts proven in the pilot are being considered for incorporation into an overall KSC Quality Surveillance System.

Schmahl, Karen E.↗
NASA NTRS2001

A Self-Diagnostic System for the M6 Accelerometer

The design of a Self-Diagnostic (SD) accelerometer system for the Space Shuttle Main Engine is presented. This retrofit system connects diagnostic electronic hardware and software to the current M6 accelerometer system. This paper discusses the general operation of the M6 accelerometer SD system and procedures for developing and evaluating the SD system. Signal processing techniques using M6 accelerometer diagnostic data are explained. Test results include diagnostic data responding to changing ambient temperature, mounting torque and base mounting impedance.

Flanagan, Patrick M.↗