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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2022

Optimization Approach for Wind Tunnel Fan Blade Strain Gage Correlation with Test Fixture Unknowns

NASA has a significant maintenance challenge with the aging wind tunnel infrastructure across the Agency. Some wind tunnel fan blades, such as those in the National Transonic Facility at NASA Langley Research Center, have been in use for far longer than their planned 10-year lifetime. No detailed analytical models of the fan blades from their initial fabrication were created. To support the fabrication of either new, nominally identical fan blades or newly designed fan blades, accurate analytical models of the existing fan blades are necessary to demonstrate an understanding of the capabilities of the existing fan blades. Additionally, the existing documentation of the testing of the existing fan blades has gaps. In this report, a process for improving test-analysis correlation for these wind tunnel fan blades is discussed. This process involved a detailed study of unknown parameters in test fixture parameters from the old and incomplete test documentation. To improve correlation, these unknown parameters were used as design variables in an optimization study to minimize the error between test data and computed structural responses. Legacy strain gage data from tests conducted in 1981 were compared with results from a finite element model created in 2019. The use of test data from 1981 was necessary because none of the existing fan blades could be spared for use in destructive structural testing. While this process was demonstrated for wind tunnel fan blades, this process could be utilized for evaluating unknowns in test fixtures for other structural test configurations.

wind tunnel↗
NASA NTRS1987

Model 360 rotor test at DNW - Review of performance and blade airload data

The results of tests on a pressure gage instrumented model rotor, performed at the Duits Nederlandse Windtunnel (DNW) are discussed. The rotor, which was a 1/5 scale model of the Boeing Vertol model 360 rotor, was tested both in the anechoic open jet test section, and in the 8 x 6 m closed test section of the DNW. The wind tunnel, the blade instrumentation, and the test conditions are described, and data on rotor performance, blade and control loads, and blade-pressure and acoustic measurements are presented.

Dadone, Leo↗
NASA NTRS1940

Full-Scale Tests of 4- and 6-Blade, Single- and Dual-Rotating Propellers, Special Report

Test of 10-foot diameter, 4- and 6-blade single- and dual-rotating propellers were conducted in the 20-foot propeller-research tunnel. The propellers were mounted at the front end of a streamline body incorporating spinners to house the hub portions. The effect of a symmetrical wing mounted in the slipstream was investigated. The blade angles investigated ranged from 20 degrees to 65 degrees; the latter setting corresponds to airplane speeds of over 500 miles per hour. The results indicate that dual-rotating propellers were from 0 to 6% more efficient than single-rotating ones; but when operating in the presence of a wing the gain was reduced about one-half. Other advantages of dual-rotating propellers were found to include greater power absorption and greater efficiency at the low V/nD operating range of high pitch propellers.

Biermann, David↗
NASA NTRS1982

Structural fatigue test results for large wind turbine blade sections

In order to provide quantitative information on the operating life capabilities of wind turbine rotor blade concepts for root-end load transfer, a series of cantilever beam fatigue tests was conducted. Fatigue tests were conducted on a laminated wood blade with bonded steel studs, a low cost steel spar (utility pole) with a welded flange, a utility pole with additional root-end thickness provided by a swaged collar, fiberglass spars with both bonded and nonbonded fittings, and, finally, an aluminum blade with a bolted steel fitting (Lockheed Mod-0 blade). Photographs, data, and conclusions for each of these tests are presented. In addition, the aluminum blade test results are compared to field failure information; these results provide evidence that the cantilever beam type of fatigue test is a satisfactory method for obtaining qualitative data on blade life expectancy and for identifying structurally underdesigned areas (hot spots).

Faddoul, J. R.↗
NASA NTRS1986

Design and initial testing of a one-bladed 30-meter-diameter rotor on the NASA/DOE mod-O wind turbine

The concept of a one-bladed horizontal-axis wind turbine has been of interest to wind turbine designers for many years. Many designs and economic analyses of one-bladed wind turbines have been undertaken by both United States and European wind energy groups. The analyses indicate significant economic advantages but at the same time, significant dynamic response concerns. In an effort to develop a broad data base on wind turbine design and operations, the NASA Wind Energy Project Office has tested a one-bladed rotor at the NASA/DOE Mod-O Wind Turbine Facility. This is the only known test on an intermediate-sized one-bladed rotor in the United States. The 15.2-meter-radius rotor consists of a tip-controlled blade and a counterweight assembly. A rigorous test series was conducted in the Fall of 1985 to collect data on rotor performance, drive train/generator dynamics, structural dynamics, and structural loads. This report includes background information on one-bladed rotor concepts, and Mod-O one-bladed rotor test configuration, supporting design analysis, the Mod-O one-blade rotor test plan, and preliminary test results.

Corrigan, R. D.↗
NASA NTRS1981

National Transonic Facility Fan Blade prepreg material characterization tests

The test program for the basic prepreg materials used in process development work and planned fabrication of the national transonic facility fan blade is presented. The basic prepreg materials and the design laminate are characterized at 89 K, room temperature, and 366 K. Characterization tests, test equipment, and test data are discussed. Material tests results in the warp direction are given for tensile, compressive, fatigue (tension-tension), interlaminar shear and thermal expansion.

Klich, P. J.↗
DOE OSTI2021

Lamination of transparent conductive adhesives for tandem solar cell applications

A transparent conductive adhesive (TCA) interlayer for mechanically stacked multijunction solar cells provides adhesive strength and electrical connection between sub-cells when stacked. The fabrication of TCA sheets from an ethyl-vinyl acetate (EVA) matrix and silver coated compliant conductive microspheres, similar to industry-standard EVA encapsulant sheets, compatible with a standard lamination process was developed. Blade coating TCA sheets using 3D printed blades and testing of vertical conduction through the interlayer with a TCA conductivity jig allowed for reproducible measurements and low-cost fabrication. The supplemental information provides design files to enable other researchers to produce their own blades and testing jigs. We identified 0.5 mm as an optimal blade height for producing lab-scale TCA sheets and 120 °C at 3 psi for 10 min as the optimal vacuum lamination process to minimize resistance and possible damage to samples. For TCA sheets with coverages between 0.75% and 9%, the series resistance was approximately 0.2 O cm2 which should result in minimal losses for one-sun photovoltaic applications.

14 SOLAR ENERGY↗
DOE OSTI2015

Structural Testing at the NWTC Helps Improve Blade Design and Increase System Reliability

Since 1990, the National Renewable Energy Laboratory's (NREL's) National Wind Technology Center (NWTC) has tested more than 150 wind turbine blades. NWTC researchers can test full-scale and subcomponent articles, conduct data analyses, and provide engineering expertise on best design practices. Structural testing of wind turbine blades enables designers, manufacturers, and owners to validate designs and assess structural performance to specific load conditions. Rigorous structural testing can reveal design and manufacturing problems at an early stage of development that can lead to overall improvements in design and increase system reliability.

17 WIND ENERGY↗
NASA NTRS1937

Tandem Air Propellers

Tests of 2-blade, adjustable-pitch, counterrotating tandem model propellers, adjusted to absorb equal power at maximum efficiency, were made at Stanford University. The characteristics, for 15 degrees, 25 degrees, 35 degrees, and 45 degrees pitch settings at 0.75 R of the forward propeller and for 8 1/2%, 15% and 30% diameter spacings, were compared with those of 2-blade and 4-blade propellers of the same blade form. The tests showed that the efficiency of the tandem propellers was from 0.5% to 4% greater than that of a 4-blade propeller and, at the high pitch settings, not appreciable inferior to that of a 2-blade propeller. It was found that the rear tandem propeller should be set at a pitch angle slightly less than that of the forward propeller to realize the condition of equal power at maximum efficiency. Under this condition the total power absorbed by the tandem propellers was from 3% to 9% more than that absorbed by the 4-blade propeller and about twice that absorbed by a 2-blade propeller.

Lesley, E.P.↗
NASA NTRS1939

Tandem Air Propellers

Tests of 2-blade, adjustable-pitch, counter rotating tandem model propellers, adjusted to absorb equal power at maximum efficiency, were made at Stanford University. The characteristics, for 15 degrees, 25 degrees, 35 degrees, and 45 degrees pitch settings at 0.75 R of the forward propeller and for 8-1/2 percent, 15 percent, and 30 percent diameter spacings, were compared with those of 2-blade and 4-blade propellers of the same blade form. The tests showed that the efficiency of the tandem propellers was from 0.5 percent to 4 percent greater than that of a 4-blade propeller and, at the high blade-angle settings, not appreciably inferior to that of a 2-blade propeller. It was found that the rear tandem propeller should be set at a blade angle slightly less than that of the forward propeller to realize the condition of equal power at maximum efficiency. Under this condition the total power absorbed by the tandem propellers was from 3 percent to 9 percent more than that absorbed by the 4-blade propeller and about twice that absorbed by a 2-blade propeller.

Lesley, E P↗
NASA NTRS1992

A demonstration of passive blade twist control using extension-twist coupling

The results from a study aimed at improving the dynamic and aerodynamic characteristics of composite rotor blades through the use of extension-twist coupling are presented. A set of low twist model-scale helicopter rotor blades was manufactured with a view towards demonstrating the passive blade twist control concept. Hover testing of the blades was conducted to measure the change in blade twist as a function of rotor speed. The blades were spun through the 0-800 rpm range, with a corresponding sweep of collective pitch to determine the effect on the blade elastic twist. Hover data were obtained for both a ballasted and unballasted blade configuration in atmospheric conditions, where maximum twist changes of 2.54 and 5.24 degrees were respectively observed. These results compared well with those from a finite element analysis of the blade, which yielded maximum twists of 3.01 and 5.61 degrees for the unballasted and ballasted blade configurations, respectively. The aerodynamic-induced effects on the blade elastic twist, determined by testing a ballasted blade configuration in a near-vacuum condition, were found to be minimal with a maximum twist difference of 0.17 degrees observed between the two test environments. The effect of collective pitch sweep on the elastic twist was minimal.

Lake, Renee C.↗
DOE OSTI2015

Structural Testing at the NWTC Helps Improve Blade Design and Increase System Reliability; NREL (National Renewable Energy Laboratory)

Since 1990, the National Renewable Energy Laboratory’s (NREL's) National Wind Technology Center (NWTC) has tested more than 150 wind turbine blades. NWTC researchers can test full-scale and subcomponent articles, conduct data analyses, and provide engineering expertise on best design practices. Structural testing of wind turbine blades enables designers, manufacturers, and owners to validate designs and assess structural performance to specific load conditions. Rigorous structural testing can reveal design and manufacturing problems at an early stage of development that can lead to overall improvements in design and increase system reliability.

17 WIND ENERGY↗
DOE OSTI2016

Improving Bending Moment Measurements on Wind Turbine Blades

Full-scale fatigue testing of wind turbine blades is conducted using resonance test techniques where the blade plus additional masses is excited at its first resonance frequency to achieve the target loading amplitude. Because there is not a direct relationship between the force applied by an actuator and the bending moment, the blade is instrumented with strain gauges that are calibrated under static loading conditions to determine the sensitivity or relationship between strain and applied moment. Then, during dynamic loading the applied moment is calculated using the strain response of the structure. A similar procedure is also used in the field to measure in-service loads on turbine blades. Because wind turbine blades are complex twisted structures and the deflections are large, there is often significant cross-talk coupling in the sensitivity of strain gauges placed on the structure. Recent work has shown that a sensitivity matrix with nonzero cross terms must be employed to find constant results when a blade is subjected to both flap and lead-lag loading. However, even under controlled laboratory conditions, potential for errors of 3 percent or more in the measured moment exist when using the typical cross-talk matrix approach due to neglecting the influence of large deformations and torsion. This is particularly critical when considering a biaxial load as would be applied on the turbine or during a biaxial fatigue test. This presentation describes these results demonstrating errors made when performing current loads measurement practices on wind turbine blades in the lab and evaluating potential improvements using enhanced cross-talk matrix approaches and calibration procedures.

17 WIND ENERGY↗
NASA NTRS2005

Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig

The Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig is an apparatus for vibration testing of turbomachine blades in a vacuum at rotational speeds from 0 to 40,000 rpm. This rig includes (1) a vertically oriented shaft on which is mounted an assembly comprising a rotor holding the blades to be tested, (2) two actively controlled heteropolar radial magnetic bearings at opposite ends of the shaft, and (3) an actively controlled magnetic thrust bearing at the upper end of the shaft. This rig is a more capable successor to a prior apparatus, denoted the Dynamic Spin Rig (DSR), that included a vertically oriented shaft with a mechanical thrust bearing at the upper end and a single actively controlled heteropolar radial magnetic bearing at the lower end.

Morrison, Carlos R.↗
NASA NTRS1984

Redesign and cascade tests of a supercritical controlled diffusion stator blade-section

A supercritical stator blade section, previously tested in cascade, and characterized by a flat-roof-top suction surface Mach number distribution, has been redesigned and retested. At near design conditions, the losses and air turning were improved over the original blade by 50 percent and 7 percent respectively. The key element in the improved performance was a small blade reshaping. This produced a continuous flow acceleration over the first one-third chord of the suction surface which successfully prevented a premature laminar separation bubble. Several recently available inviscid analysis and one fully viscous (Navier-Stokes) analysis code were used in the redesign process. The validity of these codes was enhanced by the test results.

Schmidt, J. F.↗
NASA NTRS1984

Redesign and cascade tests of a supercritical controlled diffusion stator blade-section

A supercritical stator blade section, previously tested in cascade, and characterized by a flat-roof-top suction surface Mach number distribution, has been redesigned and retested. At near design conditions, the losses and air turning were improved over the original blade by 50 percent and 7 percent, respectively. The key element in the improved performance was a small blade reshaping. This produced a continuous flow acceleration over the first one-third chord of the suction surface which successfully prevented a premature laminar separation bubble. Several recently available inviscid analysis codes and one fully viscous (Navier-Stokes) analysis code were used in the redesign process. The validity of these codes was enhanced by the test results. Previously announced in STAR as N84-22533

Schmidt, J. F.↗
NASA NTRS2003

Active Blade Vibration Control Being Developed and Tested

Gas turbine engines are currently being designed to have increased performance, lower weight and manufacturing costs, and higher reliability. Consequently, turbomachinery components, such as turbine and compressor blades, have designs that are susceptible to new vibration problems and eventual in-service failure due to high-cycle fatigue. To address this problem, researchers at the NASA Glenn Research Center are developing and testing innovative active blade vibration control concepts. Preliminary results of using an active blade vibration control system, involving a rotor supported by an active magnetic bearing in Glenn's Dynamic Spin Rig, indicate promising results (see the photograph). Active blade vibration control was achieved using feedback of blade strain gauge signals within the magnetic bearing control loop. The vibration amplitude was reduced substantially (see the graphs). Also, vibration amplitude amplification was demonstrated; this could be used to enhance structural mode identification, if desired. These results were for a nonrotating two-bladed disk. Tests for rotating blades are planned. Current and future active blade vibration control research is planned to use a fully magnetically suspended rotor and smart materials. For the fully magnetically suspended rotor work, three magnetic bearings (two radial and one axial) will be used as actuators instead of one magnetic bearing. This will allow additional degrees of freedom to be used for control. For the smart materials work, control effectors located on and off the blade will be considered. Piezoelectric materials will be considered for on-the-blade actuation, and actuator placement on a stator vane, or other nearby structure, will be investigated for off-the-blade actuation. Initial work will focus on determining the feasibility of these methods by performing basic analysis and simple experiments involving feedback control.

Johnson, Dexter↗