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NASA NTRS2002

Investigation of Dynamic Force/Vibration Transmission Characteristics of Four-Square Type Gear Durability Test Machines

In this study, design requirements for a dynamically viable, four-square type gear test machine are investigated. Variations of four-square type gear test machines have been in use for durability and dynamics testing of both parallel- and cross-axis gear set. The basic layout of these machines is illustrated. The test rig is formed by two gear pairs, of the same reduction ratio, a test gear pair and a reaction gear pair, connected to each other through shafts of certain torsional flexibility to form an efficient, closed-loop system. A desired level of constant torque is input to the circuit through mechanical (a split coupling with a torque arm) or hydraulic (a hydraulic actuator) means. The system is then driven at any desired speed by a small DC motor. The main task in hand is the isolation of the test gear pair from the reaction gear pair under dynamic conditions. Any disturbances originated at the reaction gear mesh might potentially travel to the test gearbox, altering the dynamic loading conditions of the test gear mesh, and hence, influencing the outcome of the durability or dynamics test. Therefore, a proper design of connecting structures becomes a major priority. Also, equally important is the issue of how close the operating speed of the machine is to the resonant frequencies of the gear meshes. This study focuses on a detailed analysis of the current NASA Glenn Research Center gear pitting test machine for evaluation of its resonance and vibration isolation characteristics. A number of these machines as the one illustrated has been used over last 30 years to establish an extensive database regarding the influence of the gear materials, processes surface treatments and lubricants on gear durability. This study is intended to guide an optimum design of next generation test machines for the most desirable dynamic characteristics.

Kahraman, Ahmet↗

NASA NTRS1998

High-Lift Optimization Design Using Neural Networks on a Multi-Element Airfoil

The high-lift performance of a multi-element airfoil was optimized by using neural-net predictions that were trained using a computational data set. The numerical data was generated using a two-dimensional, incompressible, Navier-Stokes algorithm with the Spalart-Allmaras turbulence model. Because it is difficult to predict maximum lift for high-lift systems, an empirically-based maximum lift criteria was used in this study to determine both the maximum lift and the angle at which it occurs. Multiple input, single output networks were trained using the NASA Ames variation of the Levenberg-Marquardt algorithm for each of the aerodynamic coefficients (lift, drag, and moment). The artificial neural networks were integrated with a gradient-based optimizer. Using independent numerical simulations and experimental data for this high-lift configuration, it was shown that this design process successfully optimized flap deflection, gap, overlap, and angle of attack to maximize lift. Once the neural networks were trained and integrated with the optimizer, minimal additional computer resources were required to perform optimization runs with different initial conditions and parameters. Applying the neural networks within the high-lift rigging optimization process reduced the amount of computational time and resources by 83% compared with traditional gradient-based optimization procedures for multiple optimization runs.

Greenman, Roxana M.↗

NASA NTRS2002

Thermal Conductivity and Sintering Behavior of Advanced Thermal Barrier Coatings

Advanced thermal barrier coatings, having significantly reduced long-term thermal conductivities, are being developed using an approach that emphasizes real-time monitoring of thermal conductivity under conditions that are engine-like in terms of temperatures and heat fluxes. This is in contrast to the traditional approach where coatings are initially optimized in terms of furnace and burner rig durability with subsequent measurement in the as-processed or furnace-sintered condition. The present work establishes a laser high-heat-flux test as the basis for evaluating advanced plasma-sprayed and physical vapor-deposited thermal barrier coatings under the NASA Ultra Efficient Engine Technology (UEET) Program. The candidate coating materials for this program are novel thermal barrier coatings that are found to have significantly reduced thermal conductivities due to an oxide-defect-cluster design. Critical issues for designing advanced low conductivity coatings with improved coating durability are also discussed.

Zhu, Dongming↗

NASA NTRS2002

Oxidation- and Creep-Enhanced Fatigue of Haynes 188 Alloy-Oxide Scale System Under Simulated Pulse Detonation Engine Conditions

The development of the pulse detonation engine (PDE) requires robust design of the engine components that are capable of enduring harsh detonation environments. In this study, a high cycle thermal fatigue test rig was developed for evaluating candidate PDE combustor materials using a CO2 laser. The high cycle thermal fatigue behavior of Haynes 188 alloy was investigated under an enhanced pulsed laser test condition of 30 Hz cycle frequency (33 ms pulse period, and 10 ms pulse width including 0.2 ms pulse spike). The temperature swings generated by the laser pulses near the specimen surface were characterized by using one-dimensional finite difference modeling combined with experimental measurements. The temperature swings resulted in significant thermal cyclic stresses in the oxide scale/alloy system, and induced extensive surface cracking. Striations of various sizes were observed at the cracked surfaces and oxide/alloy interfaces under the cyclic stresses. The test results indicated that oxidation and creep-enhanced fatigue at the oxide scale/alloy interface was an important mechanism for the surface crack initiation and propagation under the simulated PDE condition.

Zhu, Dongming↗

NASA NTRS2002

Three Dimensional CFD Analysis of the GTX Combustor

The annular combustor geometry of a combined-cycle engine has been analyzed with three-dimensional computational fluid dynamics. Both subsonic combustion and supersonic combustion flowfields have been simulated. The subsonic combustion analysis was executed in conjunction with a direct-connect test rig. Two cold-flow and one hot-flow results are presented. The simulations compare favorably with the test data for the two cold flow calculations; the hot-flow data was not yet available. The hot-flow simulation indicates that the conventional ejector-ramjet cycle would not provide adequate mixing at the conditions tested. The supersonic combustion ramjet flowfield was simulated with frozen chemistry model. A five-parameter test matrix was specified, according to statistical design-of-experiments theory. Twenty-seven separate simulations were used to assemble surrogate models for combustor mixing efficiency and total pressure recovery. ScramJet injector design parameters (injector angle, location, and fuel split) as well as mission variables (total fuel massflow and freestream Mach number) were included in the analysis. A promising injector design has been identified that provides good mixing characteristics with low total pressure losses. The surrogate models can be used to develop performance maps of different injector designs. Several complex three-way variable interactions appear within the dataset that are not adequately resolved with the current statistical analysis.

Steffen, C. J., Jr.↗

NASA NTRS2002

Performance Validation Approach for the GTX Air-Breathing Launch Vehicle

The primary objective of the GTX effort is to determine whether or not air-breathing propulsion can enable a launch vehicle to achieve orbit in a single stage. Structural weight, vehicle aerodynamics, and propulsion performance must be accurately known over the entire flight trajectory in order to make a credible assessment. Structural, aerodynamic, and propulsion parameters are strongly interdependent, which necessitates a system approach to design, evaluation, and optimization of a single-stage-to-orbit concept. The GTX reference vehicle serves this purpose, by allowing design, development, and validation of components and subsystems in a system context. The reference vehicle configuration (including propulsion) was carefully chosen so as to provide high potential for structural and volumetric efficiency, and to allow the high specific impulse of air-breathing propulsion cycles to be exploited. Minor evolution of the configuration has occurred as analytical and experimental results have become available. With this development process comes increasing validation of the weight and performance levels used in system performance determination. This paper presents an overview of the GTX reference vehicle and the approach to its performance validation. Subscale test rigs and numerical studies used to develop and validate component performance levels and unit structural weights are outlined. The sensitivity of the equivalent, effective specific impulse to key propulsion component efficiencies is presented. The role of flight demonstration in development and validation is discussed.

Trefny, Charles J.↗

NASA NTRS2002

Cyclic Failure Mechanisms of Thermal and Environmental Barrier Coating Systems Under Thermal Gradient Test Conditions

Plasma-sprayed ZrO2-8wt%Y2O3 and mullite+BSAS/Si multilayer thermal and environmental barrier coating (TBC-EBC) systems on SiC/SiC ceramic matrix composite (CMC) substrates were thermally cyclic tested under high thermal gradients using a laser high-heat-flux rig in conjunction with furnace exposure in water-vapor environments. Coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after exposure. Sintering kinetics of the coating systems were also independently characterized using a dilatometer. It was found that the coating failure involved both the time-temperature dependent sintering and the cycle frequency dependent cyclic fatigue processes. The water vapor environments not only facilitated the initial coating conductivity increases due to enhanced sintering and interface reaction, but also promoted later conductivity reductions due to the accelerated coating cracking and delamination. The failure mechanisms of the coating systems are also discussed based on the cyclic test results and are correlated to the sintering and thermal stress behavior under the thermal gradient test conditions.

Zhu, Dongming↗

NASA NTRS2002

Effect of Adventitious Carbon on the Environmental Degradation of SiC/BN/SiC Composites

Pesting remains a major obstacle to the application of SiC/SiC composites in engine service and selective degradation of the boron nitride interphase at intermediate temperatures is of primary concern. However, significant progress has been made on interphase improvement recently and we now know more about the phenomenon and ways to suppress it. By screening SiC/BN/SiC materials through characterization of strength and microstructures after exposure in a burner rig, some factors that control pesting in these composites have been determined. A key precaution is careful control of elemental carbon presence in the interphase region.

Ogbuji, L. U. J. T.↗

NASA NTRS2002

Furnace Cyclic Behavior of Plasma-Sprayed Zirconia-Yttria and Multi-Component Rare Earth Oxide Doped Thermal Barrier Coatings

Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to enable further increases in engine temperatures. However, the coating performance and durability become a major concern under the increasingly harsh thermal cycling conditions. Advanced zirconia- and hafnia-based cluster oxide thermal barrier coatings with lower thermal conductivity and improved thermal stability are being developed using a high-heat-flux laser-rig based test approach. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of numerous candidate coating materials was carried out using conventional furnace cyclic tests. In this paper, furnace thermal cyclic behavior of the advanced plasma-sprayed zirconia-yttria-based thermal barrier coatings that were co-doped with multi-component rare earth oxides was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied by using scanning electron microscopy combined with X-ray diffraction phase analysis after the furnace tests. The coating cyclic lifetime will be discussed in relation to coating phase structures, total dopant concentrations, and other properties.

Zhu, Dongming↗

NASA NTRS2002

Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

Zhu, Dongming↗

NASA NTRS2000

Cool Software for Hot Materials

Deformation Control Technology, Inc. (DCT) used a NASA SBIR contract to develop a computer modeling system for evaluating thermal barrier coatings (TBCs) beforehand. Traditional tests of TBCs required Burner Rig tests, which involved the actual application of a coating to a surface. DCT's software reduces experimentation costs as well as led to a breakthrough in understanding the role of bond coat oxidization. DCT's method has been used in a variety of turbine applications.

Source record↗

NASA NTRS2002

Pyrotechnically Operated Valves for Testing and Flight

Pyrovalves still warrant careful description of their operating characteristics, which is consistent with the NASA mission - to assure that both testing and flight hardware perform with the utmost reliability. So, until the development and qualification of the next generation of remotely controlled valves, in all likelihood based on shape memory alloy technology, pyrovalves will remain ubiquitous in controlling flow systems aloft and will possibly see growing use in ground-based testing facilities. In order to assist NASA in accomplishing this task, we propose a three-phase, three-year testing program. Phase I would set up an experimental facility, a 'test rig' in close cooperation with the staff located at the White Sands Test Facility in Southern New Mexico.

Conley, Edgar G.↗

NASA NTRS2002

Torque Splitting by a Concentric Face Gear Transmission

Tests of a 167 Kilowatt (224 Horsepower) split torque face gearbox were performed by the Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP). This paper provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA. Design, manufacture and testing of the scaled-power TRP proof-of-concept (POC) split torque gearbox followed preliminary evaluations of the concept performed early in the program. The split torque tests were run using 200 N-m (1767 in-lbs) torque input to each side of the transmission. During tests, two input pinions were slow rolled while in mesh with the two face gears. Two idler gears were also used in the configuration to recombine torque near the output. Resistance was applied at the output face gear to create the required loading conditions in the gear teeth. A system of weights, pulleys and cables were used in the test rig to provide both the input and output loading. Strain gages applied in the tooth root fillets provided strain indication used to determine torque splitting conditions at the input pinions. The final two pinion-two idler tests indicated 52% to 48% average torque split capabilities for the two pinions. During the same tests, a 57% to 43% average distribution of the torque being recombined to the upper face gear from the lower face gear was measured between the two idlers. The POC split torque tests demonstrated that face gears can be applied effectively in split torque rotorcraft transmissions, yielding good potential for significant weight, cost and reliability improvements over existing equipment using spiral bevel gearing.

Filler, Robert R.↗

NASA NTRS2002

High Temperature Corrosion of Silicon Carbide and Silicon Nitride in Water Vapor

Silicon carbide (SiC) and silicon nitride (Si3N4) are proposed for applications in high temperature combustion environments containing water vapor. Both SiC and Si3N4 react with water vapor to form a silica (SiO2) scale. It is therefore important to understand the durability of SiC, Si3N4 and SiO2 in water vapor. Thermogravimetric analyses, furnace exposures and burner rig results were obtained for these materials in water vapor at temperatures between 1100 and 1450 C and water vapor partial pressures ranging from 0.1 to 3.1 atm. First, the oxidation of SiC and Si3N4 in water vapor is considered. The parabolic kinetic rate law, rate dependence on water vapor partial pressure, and oxidation mechanism are discussed. Second, the volatilization of silica to form Si(OH)4(g) is examined. Mass spectrometric results, the linear kinetic rate law and a volatilization model based on diffusion through a gas boundary layer are discussed. Finally, the combined oxidation and volatilization reactions, which occur when SiC or Si3N4 are exposed in a water vapor-containing environment, are presented. Both experimental evidence and a model for the paralinear kinetic rate law are shown for these simultaneous oxidation and volatilization reactions.

Opila, E. J.↗

NASA NTRS2002

Performance Validation Approach for the GTX Air-Breathing Launch Vehicle

Trefny, Charles J.↗

NASA NTRS2002

Three Dimensional CFD Analysis of the GTX Combustor

The annular combustor geometry of a combined-cycle engine has been analyzed with three-dimensional computational fluid dynamics. Both subsonic combustion and supersonic combustion flowfields have been simulated. The subsonic combustion analysis was executed in conjunction with a direct-connect test rig. Two cold-flow and one hot-flow results are presented. The simulations compare favorably with the test data for the two cold flow calculations; the hot-flow data was not yet available. The hot-flow simulation Indicates that the conventional ejector-ramjet cycle would not provide adequate mixing at the conditions tested. The supersonic combustion ramjet flowfield was simulated with frozen chemistry model. A five-parameter test matrix was specified, according to statistical design-of-experiments theory. Twenty-seven separate simulations were used to assemble surrogate models for combustor mixing efficiency and total pressure recovery. Scramjet injector design parameters (injector angle, location, and fuel split) as well as mission variables (total fuel mass flow and freestream Mach number) were included in the analysis. A promising injector design has been identified that provides good mixing characteristics with low total pressure losses. The surrogate models can be used to develop performance maps of different injector designs. Several complex three-way variable interactions appear within the dataset that are not adequately resolved with the current statistical analysis.

Steffen, C. J., Jr.↗

NASA NTRS2002

Application of Function-Failure Similarity Method to Rotorcraft Component Design

Performance and safety are the top concerns of high-risk aerospace applications at NASA. Eliminating or reducing performance and safety problems can be achieved with a thorough understanding of potential failure modes in the designs that lead to these problems. The majority of techniques use prior knowledge and experience as well as Failure Modes and Effects as methods to determine potential failure modes of aircraft. During the design of aircraft, a general technique is needed to ensure that every potential failure mode is considered, while avoiding spending time on improbable failure modes. In this work, this is accomplished by mapping failure modes to specific components, which are described by their functionality. The failure modes are then linked to the basic functions that are carried within the components of the aircraft. Using this technique, designers can examine the basic functions, and select appropriate analyses to eliminate or design out the potential failure modes. The fundamentals of this method were previously introduced for a simple rotating machine test rig with basic functions that are common to a rotorcraft. In this paper, this technique is applied to the engine and power train of a rotorcraft, using failures and functions obtained from accident reports and engineering drawings.

Roberts, Rory A.↗

NASA NTRS2002

Advanced Nacelle Acoustic Lining Concepts Development

The work reported in this document consisted of six distinct liner technology development subtasks: 1) Analysis of Model Scale ADP Fan Duct Lining Data (Boeing): An evaluation of an AST Milestone experiment to demonstrate 1995 liner technology superiority relative to that of 1992 was performed on 1:5.9 scale model fan rig (Advanced Ducted Propeller) test data acquired in the NASA Glenn 9 x 15 foot wind tunnel. The goal of 50% improvement was deemed satisfied. 2) Bias Flow Liner Investigation (Boeing, VCES): The ability to control liner impedance by low velocity bias flow through liner was demonstrated. An impedance prediction model to include bias flow was developed. 3) Grazing Flow Impedance Testing (Boeing): Grazing flow impedance tests were conducted for comparison with results achieved at four different laboratories. 4) Micro-Perforate Acoustic Liner Technology (BFG, HAE, NG): Proof of concept testing of a "linear liner." 5) Extended Reaction Liners (Boeing, NG): Bandwidth improvements for non-locally reacting liner were investigated with porous honeycomb core test liners. 6) Development of a Hybrid Active/Passive Lining Concept (HAE): Synergism between active and passive attenuation of noise radiated by a model inlet was demonstrated.

Bielak, G.↗