Summary of 65-series compressor-blade low-speed cascade data by use of the carpet-plotting technique
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Felix, A Richard↗
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Calibration of a V-Cone for Low Mass Flows For Small Core Compressor Research
Advancements in core compressor technologies are necessary for next generation, high Overall Pressure Ratio (OPR) turbofan engines. High pressure compressors (HPCs) for future engines are being designed with exit corrected mass flow rates less than 2.25 kg/s (5 lbm/s). In order to accurately measure the performance of these advanced designs, high accuracy measurements are needed in test facilities. The W7 High Speed Multistage Axial Compressor Facility at NASA Glenn Research Center has been used to acquire data for advanced compressor designs. This facility utilizes an advanced differential pressure flow meter called a V-Cone. The facility has historically tested components with physical mass flow rates in the range of 27 to 45 kg/s (60 to 100 lbm/s). As such, when the V-Cone was calibrated prior to installation, the calibrations focused on higher mass flow rates, and uncertainties in that regime range from 0.5% to 0.85%. However, for low mass flow rates under 9 kg/s (20 lbm/s), expected in tests of advanced high OPR HPCs rear stages, the uncertainties of the V-Cone exceed 2.5%. To address this, using a method similar to that utilized by the National Institute of Standards and Technology, an array of Critical Flow Venturi Nozzles (CFVs) was installed in the W7 test section and used to calibrate the V-Cone in 0.5 kg/s (1 lbm/s) increments up to 10.5 kg/s (23 lbm/s). This effort details the measurements and uncertainties associated with this calibration which resulted in a final uncertainty of the V-Cone measurements under 1%.
Measurement Uncertainty↗
Performance of the 19XB 10-Stage Axial-Flow Compressor with Altered Blade Angles
Previous performance data of the 19XB axial-flow compressor indicated that the outlet guide vanes and possibly the inlet guide vanes were stalling. Calculations were made to determine if these adverse conditions could be eliminated and if the manufacturer's design specifications could be more nearly approached by altering the blade angles of the first few compression stages as well as the outlet guide vanes. With the blade angles altered, experimental data were taken at compressor speeds of 8500 to 17,000 rpm with inlet-air conditions of 7.4 inches of mercury absolute and 59 0 F. The temperature-rise efficiency increased with speed from 0.70 at 8500 rpm to 0.74 at 13,600 rpm and dropped gradually to 0.70 at 17,000 rpm. At the design speed of 17,000 rpm, the pressure ratio at the peak efficiency point was 3.63. The maximum pressure ratio at design speed was 4.15 at an equivalent weight flow of 29.8 pounds per second. The altered compressor operated very .near the design specifications of pressure ratio and equivalent weight flow. At the high speeds, the peak adiabatic temperature-rise efficiency was increased 0.02 to 0,06 by altering the blade angles. The peak pressure ratio was increased 0.29 at design speed (17,000 rpm) and 0.05 and 0.13 at 11,900 and 13,600 rpm, respectively. The equivalent weight flow through the altered compressor was reduced 2 pounds per second at 15,300 and 17,000 rpm, as was expected from the design calculations. As extreme caution was taken not to surge the compressor violently, the point of minimum air flow may not have been reached in the present investigation and in a previous investigation. A true comparison of the pressure ratios obtained at the high speeds therefore cannot be made.
Downing, Richard M.↗
Toward Understanding Tip Leakage Flows in Small Compressor Cores Including Stator Leakage Flow
The focus of this work was to provide additional data to supplement the work reported in NASA/CR-2015-218868 (Berdanier and Key, 2015b). The aim of that project was to characterize the fundamental flow physics and the overall performance effects due to increased rotor tip clearance heights in axial compressors. Data have been collected in the three-stage axial research compressor at Purdue University with a specific focus on analyzing the multistage effects resulting from the tip leakage flow. Three separate rotor tip clearances were studied with nominal tip clearance gaps of 1.5 percent, 3.0 percent, and 4.0 percent based on a constant annulus height. Overall compressor performance was previously investigated at four corrected speedlines (100 percent, 90 percent, 80 percent, and 68 percent) for each of the three tip clearance configurations. This study extends the previously published results to include detailed steady and time-resolved pressure data at two loading conditions, nominal loading (NL) and high loading (HL), on the 100 percent corrected speedline for the intermediate clearance level (3.0 percent). Steady detailed radial traverses of total pressure at the exit of each stator row are supported by flow visualization techniques to identify regions of flow recirculation and separation. Furthermore, detailed radial traverses of time-resolved total pressures at the exit of each rotor row have been measured with a fast-response pressure probe. These data were combined with existing three-component velocity measurements to identify a novel technique for calculating blockage in a multistage compressor. Time-resolved static pressure measurements have been collected over the rotor tips for all rotors with each of the three tip clearance configurations for up to five loading conditions along the 100 percent corrected speedline using fast-response piezoresistive pressure sensors. These time-resolved static pressure measurements reveal new knowledge about the trajectory of the tip leakage flow through the rotor passage. Further, these data extend previous measurements identifying a modulation of the tip leakage flow due to upstream stator wake propagation. Finally, a novel instrumentation technique has been implemented to measure pressures in the shrouded stator cavities. These data provide boundary conditions relating to the flow across the shrouded stator knife seal teeth. Moreover, the utilization of fast-response pressure sensors provides a new look at the time-resolved pressure field, leading to instantaneous differential pressures across the seal teeth. Ultimately, the data collected for this project represent a unique data set which contributes to build a better understanding of the tip leakage flow field and its associated loss mechanisms. These data will facilitate future engine design goals leading to small blade heights in the rear stages of high pressure compressors and aid in the development of new blade designs which are desensitized to the performance penalties attributed to rotor tip leakage flows.
Berdanier, Reid A.↗
An analysis of the rotor blade stresses of the three stage compressor of the Ames Research Center 11- by 11-foot transonic wind tunnel
The static and dynamic rotor blade stresses of the three stage compressor were measured. Data are presented in terms of total blade stress for the complete operational range of compressor speeds and tunnel total pressures. Modal frequencies and variations with tunnel conditions were measured. Phase angles and coherences between various gage combinations are also presented. Recommendations for improvements are given for future rotor blade experimental investigations.
Dods, J. B., Jr.↗
Data for Design of Entrance Vanes from Two-Dimensional Tests of Airfoils in Cascade
As a part of a program of the NACA directed toward increasing the efficiency of compressors and turbines, data were obtained for application to the design of entrance vanes for axfax-flow compressors or turbines. A series of blower-blade sections with relatively high critical speeds have been developed for turning air efficiently from 0 deg to 80 deg starting with an axial direction. Tests were made of five NACA 65-series blower blades (modified NACA 65(216)-010 airfoils) and of four experimentally designed blower blades in a stationary cascade at low Mach numbers. The turning effectiveness and the pressure distributions of these blade sections at various angles of attack were evaluated over a range of solidities near 1. Entrance-vane design charts are presented that give a blade section and angle of attack for any desired turning angle. The blades thus obtained operate with peak-free pressure distributions. Approximate critical Mach numbers were calculated from the pressure distributions.
FLOW-VANES, GUIDE↗
Experimental Investigation of Rotating Stall in a Research Multistage Axial Compressor
A collection of experimental data acquired in the NASA low-speed multistage axial compressor while operated in rotating stall is presented in this paper. The compressor was instrumented with high-response wall pressure modules and a static pressure disc probe for in-flow measurement, and a split-fiber probe for simultaneous measurements of velocity magnitude and flow direction. The data acquired to-date have indicated that a single fully developed stall cell rotates about the flow annulus at 50.6% of the rotor speed. The stall phenomenon is substantially periodic at a fixed frequency of 8.29 Hz. It was determined that the rotating stall cell extends throughout the entire compressor, primarily in the axial direction. Spanwise distributions of the instantaneous absolute flow angle, axial and tangential velocity components, and static pressure acquired behind the first rotor are presented in the form of contour plots to visualize different patterns in the outer (midspan to casing) and inner (hub to mid-span) flow annuli during rotating stall. In most of the cases observed, the rotating stall started with a single cell. On occasion, rotating stall started with two emerging stall cells. The root cause of the variable stall cell count is unknown, but is not attributed to operating procedures.
Lepicovsky, Jan↗
Application of a Split-Fiber Probe to Velocity Measurement in the NASA Research Compressor
A split-fiber probe was used to acquire unsteady data in a research compressor. The probe has two thin films deposited on a quartz cylinder 200 microns in diameter. A split-fiber probe allows simultaneous measurement of velocity magnitude and direction in a plane that is perpendicular to the sensing cylinder, because it has its circumference divided into two independent parts. Local heat transfer considerations indicated that the probe direction characteristic is linear in the range of flow incidence angles of +/- 35. Calibration tests confirmed this assumption. Of course, the velocity characteristic is nonlinear as is typical in thermal anemometry. The probe was used extensively in the NASA Glenn Research Center (GRC) low-speed, multistage axial compressor, and worked reliably during a test program of several months duration. The velocity and direction characteristics of the probe showed only minute changes during the entire test program. An algorithm was developed to decompose the probe signals into velocity magnitude and velocity direction. The averaged unsteady data were compared with data acquired by pneumatic probes. An overall excellent agreement between the averaged data acquired by a split-fiber probe and a pneumatic probe boosts confidence in the reliability of the unsteady content of the split-fiber probe data. To investigate the features of unsteady data, two methods were used: ensemble averaging and frequency analysis. The velocity distribution in a rotor blade passage was retrieved using the ensemble averaging method. Frequencies of excitation forces that may contribute to high cycle fatigue problems were identified by applying a fast Fourier transform to the absolute velocity data.
Lepicovsky, Jan↗
Prediction of off-design performance of multistage compressors
Three techniques are presented for estimating compressor off-design performance. The first method, which is based on blade-element theory, is useful for obtaining only a small part of the compressor map over which all blade elements in the compressor operate unstalled. The second method, which involves individual stage performance curves and a stage-by-stage calculation, is useful for estimating the performance of a compressor for which reliable stage performance curves are available. The third method, which is based on over-all performance data of existing compressors, may be used to estimate the complete performance map of a new compressor if the compressor design conditions are specific.
PERFORMANCE PREDICTION↗
Single-stage experimental evaluation of compressor blading with slots and vortex generators. Part 4 - Supplemental data for stage 4
Supplementary data tables for single stage experimental evaluation of compressor blading with slots and vortex generators
Brent, J. A.↗
Refining the W1 and SE1 Facilities
The Engine Research Building (ERB) houses more than 60 test rigs that study all aspects of engine development. By working with Mary Gibson in the SE1 and W1A Turbine Facilities, I became aware of her responsibilities and better acquainted with the inner workings of the ERB. The SE1 Supersonic/Subsonic Wind Tunnel Facility contains 2 small wind tunnels. The first tunnel uses an atmospheric inlet, while the second uses treated 40-psig air. Both of the tunnels are capable of subsonic and supersonic operation. An auxiliary air supply and exhaust piping providing both test sections with suction, blowing, and crossfire capabilities. The current configuration of SE1 consists of a curved diffuser that studies the blockage along the endwalls. The W1A Low Speed Compressor Facility provides insight for the complex flow phenomena within its 4-stage axial compressor, sand the data obtained from W 1A is used to develop advanced models for fluid dynamic assessment. W1A is based off of a low speed research compressor developed by GE in the 1950's. This compressor has a removable casing treatment under rotor 1, which allows for various tip treatment studies. The increased size and low speed allows instrumentation to be located in the compressor s complex flow paths. Air enters the facility through a filtered roof vent, conditioned for temperature and turbulence, and then passed through the compressor W1A is described as a dynamic facility with many projects taking place simultaneously. This current environment makes it challenging to follow the various affairs that are taking place within the area. During my first 4 weeks at the NASA Glenn Research Center, I have assisted Mary Gibson in multiple tasks such as facility documents, record keeping, maintenance and upgrades. The facility has lube systems for its gearbox and compressor. These systems are critical in the successful operation of the facility. I was assigned the task of creating a facility estimate list, which included the filters and strainers required for the compressor. For my remaining time spent here, we expect to complete a facility parts listing and a virtual project summary so that W1A and SE1 will become ergonomic facilities that will make it easier for people to observe the capabilities and history of the area and the employees that operate. Bolstering our efforts in achieving these goal are the online technical tutorials, software such as Microsoft Excel. Macromedia Flash MX Macromedia Dreamweaver MX, Photoshop 6.0 and the assistance of several NASA employees.
Chambers, Rodney D.↗
Dynamic data acquisition, reduction, and analysis for the identification of high-speed compressor component post-stability characteristics
A compressor test was conducted in which transient data were obtained for the purpose of identifying the high-speed post-stability characteristics. The transient, surge-cycle nature of high-speed post-stability operation precludes the possibility of obtaining the characteristics in a steady-state manner, as is possible during low-speed poststability operation, which is characterized by quasi-steady rotating-stall behavior. Specialized compressor instrumentation was developed and was used to obtain the necessary surge-cycle performance data, which were then digitized, filtered, and analyzed. The high-speed post-stability characteristics were obtained through the use of a maximum likelihood-parameter estimation technique. The estimated characteristics were found to be insensitive to the presence of measurement noise and unmodelled system dynamics, but the compressor time-response constants, which were also estimated, were more sensitive to these same disturbances.
Dvorak, S. D.↗
Development of compressor end seals stator interstage seals, and stator pivot seals in advanced air breathing propulsion systems. Part 2: Experimental data and analysis
Performance tests of compressor seals and stator pivot seals used with air breathing propulsion systems - Part 2
Hawkins, R. M.↗
Preliminary Results of Altitude-Wind-Tunnel Investigation of X24C-4B Turbojet Engine. IV - Performance of Modified Compressor: Performance of Modified Compressor - Part 4
The performance of the 11-stage axial-flow compressor, modified to improve the compressor-outlet velocity, in a revised X24C-4B turbojet engine is presented and compared with the performance of the compressor in the original engine. Performance data were obtained from an investigation of the revised engine in the MACA Cleveland altitude wind tunnel. Compressor performance data were obtained for engine operation with four exhaust nozzles of different outlet area at simulated altitudes from 15,OOO to 45,000 feet, simulated flight Mach numbers from 0.24 to 1.07, and engine speeds from 4000 to 12,500 rpm. The data cover a range of corrected engine speeds from 4100 to 13,500 rpm, which correspond to compressor Mach numbers from 0.30 to 1.00.
Thorman, H. Carl↗
A General Framework for Error-controlled Unstructured Scientific Data Compression
Data compression plays a key role in reducing storage and I/O costs. Traditional lossy methods primarily target data on rectilinear grids and cannot leverage the spatial coherence in unstructured mesh data, leading to suboptimal compression ratios. We present a multi-component, error-bounded compression framework designed to enhance the compression of floating-point unstructured mesh data, which is common in scientific applications. Our approach involves interpolating mesh data onto a rectilinear grid and then separately compressing the grid interpolation and the interpolation residuals. This method is general, independent of mesh types and typologies, and can be seamlessly integrated with existing lossy compressors for improved performance. We evaluated our framework across twelve variables from two synthetic datasets and two real-world simulation datasets. The results indicate that the multi-component framework consistently outperforms state-of-the-art lossy compressors on unstructured data, achieving, on average, a 2.3 − 3.5× improvement in compression ratios, with error bounds ranging from 1 × 10 the −6 to 1×10−2. We further investigate impact of hyperparameters, such as grid spacing and error allocation, to deliver optimal compression ratios in diverse datasets.
Gong, Qian↗
Modeling of a Turbofan Engine with Ice Crystal Ingestion in the NASA Propulsion System Laboratory
The main focus of this study is to apply a computational tool for the flow analysis of the turbine engine that has been tested with ice crystal ingestion in the Propulsion Systems Laboratory (PSL) at NASA Glenn Research Center. The PSL has been used to test a highly instrumented Honeywell ALF502R-5A (LF11) turbofan engine at simulated altitude operating conditions. Test data analysis with an engine cycle code and a compressor flow code was conducted to determine the values of key icing parameters, that can indicate the risk of ice accretion, which can lead to engine rollback (un-commanded loss of engine thrust). The full engine aerothermodynamic performance was modeled with the Honeywell Customer Deck specifically created for the ALF502R-5A engine. The mean-line compressor flow analysis code, which includes a code that models the state of the ice crystal, was used to model the air flow through the fan-core and low pressure compressor. The results of the compressor flow analyses included calculations of the ice-water flow rate to air flow rate ratio (IWAR), the local static wet bulb temperature, and the particle melt ratio throughout the flow field. It was found that the assumed particle size had a large effect on the particle melt ratio, and on the local wet bulb temperature. In this study the particle size was varied parametrically to produce a non-zero calculated melt ratio in the exit guide vane (EGV) region of the low pressure compressor (LPC) for the data points that experienced a growth of blockage there, and a subsequent engine called rollback (CRB). At data points where the engine experienced a CRB having the lowest wet bulb temperature of 492 degrees Rankine at the EGV trailing edge, the smallest particle size that produced a non-zero melt ratio (between 3 percent - 4 percent) was on the order of 1 micron. This value of melt ratio was utilized as the target for all other subsequent data points analyzed, while the particle size was varied from 1 micron - 9.5 microns to achieve the target melt ratio. For data points that did not experience a CRB which had static wet bulb temperatures in the EGV region below 492 degrees Rankine, a non-zero melt ratio could not be achieved even with a 1 micron ice particle size. The highest value of static wet bulb temperature for data points that experienced engine CRB was 498 degrees Rankine with a particle size of 9.5 microns. Based on this study of the LF11 engine test data, the range of static wet bulb temperature at the EGV exit for engine CRB was in the narrow range of 492 degrees Rankine - 498 degrees Rankine , while the minimum value of IWAR was 0.002. The rate of blockage growth due to ice accretion and boundary layer growth was estimated by scaling from a known blockage growth rate that was determined in a previous study. These results obtained from the LF11 engine analysis formed the basis of a unique “icing wedge.”
Turbo engine↗
Experimental Investigation of a Five-stage Axial-flow Research Compressor with Transonic Rotors in All Stages III : Interstage Data and Individual Stage Performance Characteristics
For use in computing the detailed performance parameters of individual blade rows of a multistage compressor, radial distributions of total pressure, total temperature, static pressure and air-flow angle are tabulated. The data cover a range of air flow from choke to the approximate surge limit for equivalent rotor speeds from 70 to 100 percent of design. Equivalent stage performance curves determined from the radial survey measurements indicate both the individual performance and the matching of the stages at the speeds investigated.
Sandercock, Donald M↗
Optical Calibration Process Developed for Neural-Network-Based Optical Nondestructive Evaluation Method
A completely optical calibration process has been developed at Glenn for calibrating a neural-network-based nondestructive evaluation (NDE) method. The NDE method itself detects very small changes in the characteristic patterns or vibration mode shapes of vibrating structures as discussed in many references. The mode shapes or characteristic patterns are recorded using television or electronic holography and change when a structure experiences, for example, cracking, debonds, or variations in fastener properties. An artificial neural network can be trained to be very sensitive to changes in the mode shapes, but quantifying or calibrating that sensitivity in a consistent, meaningful, and deliverable manner has been challenging. The standard calibration approach has been difficult to implement, where the response to damage of the trained neural network is compared with the responses of vibration-measurement sensors. In particular, the vibration-measurement sensors are intrusive, insufficiently sensitive, and not numerous enough. In response to these difficulties, a completely optical alternative to the standard calibration approach was proposed and tested successfully. Specifically, the vibration mode to be monitored for structural damage was intentionally contaminated with known amounts of another mode, and the response of the trained neural network was measured as a function of the peak-to-peak amplitude of the contaminating mode. The neural network calibration technique essentially uses the vibration mode shapes of the undamaged structure as standards against which the changed mode shapes are compared. The published response of the network can be made nearly independent of the contaminating mode, if enough vibration modes are used to train the net. The sensitivity of the neural network can be adjusted for the environment in which the test is to be conducted. The response of a neural network trained with measured vibration patterns for use on a vibration isolation table in the presence of various sources of laboratory noise is shown. The output of the neural network is called the degradable classification index. The curve was generated by a simultaneous comparison of means, and it shows a peak-to-peak sensitivity of about 100 nm. The following graph uses model generated data from a compressor blade to show that much higher sensitivities are possible when the environment can be controlled better. The peak-to-peak sensitivity here is about 20 nm. The training procedure was modified for the second graph, and the data were subjected to an intensity-dependent transformation called folding. All the measurements for this approach to calibration were optical. The peak-to-peak amplitudes of the vibration modes were measured using heterodyne interferometry, and the modes themselves were recorded using television (electronic) holography.
Decker, Arthur J.↗