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NASA NTRS2005

Dual-Band Deramp Radar Design for Ocean Current Measurements

A mission has been proposed to remotely measure ocean surface currents and surface wind velocities. It will provide the highest resolution and repeat time of these measurements to date for ocean current models with scientific and societal applications. A ground-based experimental radar unit is needed for proof of concept. The proposed experiment set up is to mount the radar on an oil rig to imitate satellite data acquisition. This summer, I completed the radar design. The design employs chirp/deramp topology with simultaneous transmit/receive channels. These two properties allow large system bandwidth, extended sample time, close range imaging, and low sampling rate. The radar operates in the Ku and Ka microwave bands, at 13.5 and 35.5 GHz, respectively, with a system bandwidth of 300 MHz. I completed the radar frequency analysis and research on potential components and antenna configurations. Subsequent work is needed to procure components, as well as to build, test, and deploy the radar.

Haynes, Mark S.↗

NASA NTRS2006

High Fidelity System Simulation of Multiple Components in Support of the UEET Program

The High Fidelity System Simulation effort has addressed various important objectives to enable additional capability within the NPSS framework. The scope emphasized High Pressure Turbine and High Pressure Compressor components. Initial effort was directed at developing and validating intermediate fidelity NPSS model using PD geometry and extended to high-fidelity NPSS model by overlaying detailed geometry to validate CFD against rig data. Both "feedforward" and feedback" approaches of analysis zooming was employed to enable system simulation capability in NPSS. These approaches have certain benefits and applicability in terms of specific applications "feedback" zooming allows the flow-up of information from high-fidelity analysis to be used to update the NPSS model results by forcing the NPSS solver to converge to high-fidelity analysis predictions. This apporach is effective in improving the accuracy of the NPSS model; however, it can only be used in circumstances where there is a clear physics-based strategy to flow up the high-fidelity analysis results to update the NPSS system model. "Feed-forward" zooming approach is more broadly useful in terms of enabling detailed analysis at early stages of design for a specified set of critical operating points and using these analysis results to drive design decisions early in the development process.

Plybon, Ronald C.↗

NASA NTRS2006

Thrust Stand for Electric Propulsion Performance Evaluation

An electric propulsion thrust stand capable of supporting testing of thrusters having a total mass of up to 125 kg and producing thrust levels between 100 microN to 1 N has been developed and tested. The design features a conventional hanging pendulum arm attached to a balance mechanism that converts horizontal deflections produced by the operating thruster into amplified vertical motion of a secondary arm. The level of amplification is changed through adjustment of the location of one of the pivot points linking the system. Response of the system depends on the relative magnitudes of the restoring moments applied by the displaced thruster mass and the twisting torsional pivots connecting the members of the balance mechanism. Displacement is measured using a non-contact, optical linear gap displacement transducer and balance oscillatory motion is attenuated using a passive, eddy-current damper. The thrust stand employs an automated leveling and thermal control system. Pools of liquid gallium are used to deliver power to the thruster without using solid wire connections, which can exert undesirable time-varying forces on the balance. These systems serve to eliminate sources of zero-drift that can occur as the stand thermally or mechanically shifts during the course of an experiment. An in-situ calibration rig allows for steady-state calibration before, during and after thruster operation. Thrust measurements were carried out on a cylindrical Hall thruster that produces mN-level thrust. The measurements were very repeatable, producing results that compare favorably with previously published performance data, but with considerably smaller uncertainty.

Polzin, Kurt A.↗

NASA NTRS2006

AST Critical Propulsion and Noise Reduction Technologies for Future Commercial Subsonic Engines Area of Interest 1.0: Reliable and Affordable Control Systems

The General Electric Reliable and Affordable Controls effort under the NASA Advanced Subsonic Technology (AST) Program has designed, fabricated, and tested advanced controls hardware and software to reduce emissions and improve engine safety and reliability. The original effort consisted of four elements: 1) a Hydraulic Multiplexer; 2) Active Combustor Control; 3) a Variable Displacement Vane Pump (VDVP); and 4) Intelligent Engine Control. The VDVP and Intelligent Engine Control elements were cancelled due to funding constraints and are reported here only to the state they progressed. The Hydraulic Multiplexing element developed and tested a prototype which improves reliability by combining the functionality of up to 16 solenoids and servo-valves into one component with a single electrically powered force motor. The Active Combustor Control element developed intelligent staging and control strategies for low emission combustors. This included development and tests of a Controlled Pressure Fuel Nozzle for fuel sequencing, a Fuel Multiplexer for individual fuel cup metering, and model-based control logic. Both the Hydraulic Multiplexer and Controlled Pressure Fuel Nozzle system were cleared for engine test. The Fuel Multiplexer was cleared for combustor rig test which must be followed by an engine test to achieve full maturation.

Myers, William↗

NASA NTRS2006

A Resonant Synchronous Vibration Based Approach for Rotor Imbalance Detection

This paper presents a methodology of detecting rotor imbalances, such as mass imbalance and crack-induced imbalance, using shaft synchronous vibrations. An iterative scheme is developed to identify parameters from measured synchronous vibration data. A detection system is integrated by using state-of-the-art commercial analysis equipment. A laboratory rotor test rig is used to verify the system integration and algorithm validation. A real engine test has been carried out and the results are reported.

Luo, Huangeng↗

NASA NTRS2006

Ceramic Composite Development for Gas Turbine Engine Hot Section Components

The development of ceramic materials for incorporation into the hot section of gas turbine engines has been ongoing for about fifty years. Researchers have designed, developed, and tested ceramic gas turbine components in rigs and engines for automotive, aero-propulsion, industrial, and utility power applications. Today, primarily because of materials limitations and/or economic factors, major challenges still remain for the implementation of ceramic components in gas turbines. For example, because of low fracture toughness, monolithic ceramics continue to suffer from the risk of failure due to unknown extrinsic damage events during engine service. On the other hand, ceramic matrix composites (CMC) with their ability to display much higher damage tolerance appear to be the materials of choice for current and future engine components. The objective of this paper is to briefly review the design and property status of CMC materials for implementation within the combustor and turbine sections for gas turbine engine applications. It is shown that although CMC systems have advanced significantly in thermo-structural performance within recent years, certain challenges still exist in terms of producibility, design, and affordability for commercial CMC turbine components. Nevertheless, there exist some recent successful efforts for prototype CMC components within different engine types.

DiCarlo, James A.↗

NASA NTRS2006

Ceramic Matrix Composite Vane Subelement Burst Testing

Burst tests were performed on Ceramic Matrix Composite (CMC) vane specimens, manufactured by two vendors, under the Ultra Efficient Engine Technology (UEET) project. Burst specimens were machined from the ends of 76mm long vane sub-elements blanks and from High Pressure Burner Rig (HPBR) tested specimens. The results of burst tests will be used to compare virgin specimens with specimens that have had an Environmental Barrier Coating (EBC) applied, both HPBR tested and untested, as well as a comparison between vendors.

Brewer, David N.↗

NASA NTRS2006

Flow and Noise Control in High Speed and High Reynolds Number Jets Using Plasma Actuators

The idea of manipulating flow to change its characteristics is over a century old. Manipulating instabilities of a jet to increase its mixing and to reduce its radiated noise started in the 1970s. While the effort has been successful in low-speed and low Reynolds number jets, available actuators capabilities in terms of their amplitude, bandwidth, and phasing have fallen short in control of high-speed and high Reynolds number jets of practical interest. Localized arc filament plasma actuators have recently been developed and extensively used at Gas Dynamics and Turbulence Laboratory (GDTL) for control of highspeed and high Reynolds number jets. While the technique has been quite successful and is very promising, all the work up to this point had been carried out using small high subsonic and low supersonic jets from a 2.54 cm diameter nozzle exit with a Reynolds number of about a million. The preliminary work reported in this paper is a first attempt to evaluate the scalability of the technique. The power supply/plasma generator was designed and built in-house at GDTL to operate 8 actuators simultaneously over a large frequency range (0 to 200 kHz) with independent control over phase and duty cycle of each actuator. This allowed forcing the small jet at GDTL with azimuthal modes m = 0, 1, 2, 3, plus or minus 1, plus or minus 2, and plus or minus 4 over a large range of frequencies. This power supply was taken to and used, with minor modifications, at the NASA Nozzle Acoustic Test Rig (NATR). At NATR, 32 actuators were distributed around the 7.5 in. nozzle (a linear increase with nozzle exit diameter would require 60 actuators). With this arrangement only 8 actuators could operate simultaneously, thus limiting the forcing of the jet at NATR to only three azimuthal modes m = plus or minus 1, 4, and 8. Very preliminary results at NATR indicate that the trends observed in the larger NASA facility in terms of the effects of actuation frequency and azimuthal modes are similar in both small GDTL and larger NASA jets. However, the actuation authority seems to fall short in the larger jet at higher Mach numbers, resulting in decreased amplitude response compared to the small jet, which is attributed at this point to the lack of sufficient number of actuators. The preliminary results seem also to suggest that amplitude of actuation tones is similar in both the small and larger jets.

Samimy, M.↗

NASA NTRS2006

Brush Seals for Improved Steam Turbine Performance

GE Energy has retrofitted brush seals into more than 19 operating steam turbines. Brush seals offer superior leakage control compared to labyrinth seals, owing to their compliant nature and ability to maintain very tight clearances to the rotating shaft. Seal designs have been established for steam turbines ranging in size from 12 MW to over 1200 MW, including fossil, nuclear, combined-cycle and industrial applications. Steam turbines present unique design challenges that must be addressed to ensure that the potential performance benefits of brush seals are realized. Brush seals can have important effects on the overall turbine system that must be taken into account to assure reliable operation. Subscale rig tests are instrumental to understanding seal behavior under simulated steam-turbine operating conditions, prior to installing brush seals in the field. This presentation discusses the technical challenges of designing brush seals for steam turbines; subscale testing; performance benefits of brush seals; overall system effects; and field applications.

Turnquist, Norman↗

NASA NTRS2006

High Misalignment Carbon Seals for the Fan Drive Gear System Technologies

Aircraft engines of the future will require capability bearing compartment seals than found in current engines. Geared systems driving the fan will be subjected to inertia and gyroscopic forces resulting in extremely high angular and radial misalignments. Because of the high misalignment levels, compartment seals capable of accommodating angularities and eccentricities are required. Pratt & Whitney and Stein Seal Company selected the segmented circumferential carbon seal as the best candidate to operate at highly misaligned conditions. Initial seal tests established the misalignment limits of the current technology circumferential seal. From these results a more compliant seal configuration was conceived, designed, fabricated, and tested. Further improvements to the design are underway and plans are to conduct a durability test of the next phase configuration. A technical approach is presented, including design modification to a "baseline"seal, carbon grade selection, test rig configuration, test plan and results of analysis of seal testing.

Shaughnessy, Dennis↗

NASA NTRS2007

Probabilistic Analysis of Space Shuttle Body Flap Actuator Ball Bearings

A probabilistic analysis, using the 2-parameter Weibull-Johnson method, was performed on experimental life test data from space shuttle actuator bearings. Experiments were performed on a test rig under simulated conditions to determine the life and failure mechanism of the grease lubricated bearings that support the input shaft of the space shuttle body flap actuators. The failure mechanism was wear that can cause loss of bearing preload. These tests established life and reliability data for both shuttle flight and ground operation. Test data were used to estimate the failure rate and reliability as a function of the number of shuttle missions flown. The Weibull analysis of the test data for a 2-bearing shaft assembly in each body flap actuator established a reliability level of 99.6 percent for a life of 12 missions. A probabilistic system analysis for four shuttles, each of which has four actuators, predicts a single bearing failure in one actuator of one shuttle after 22 missions (a total of 88 missions for a 4-shuttle fleet). This prediction is comparable with actual shuttle flight history in which a single actuator bearing was found to have failed by wear at 20 missions.

Oswald, Fred B.↗

NASA NTRS2007

Space and Terrestrial Power System Integration Optimization Code BRMAPS for Gas Turbine Space Power Plants With Nuclear Reactor Heat Sources

In view of the difficult times the US and global economies are experiencing today, funds for the development of advanced fission reactors nuclear power systems for space propulsion and planetary surface applications are currently not available. However, according to the Energy Policy Act of 2005 the U.S. needs to invest in developing fission reactor technology for ground based terrestrial power plants. Such plants would make a significant contribution toward drastic reduction of worldwide greenhouse gas emissions and associated global warming. To accomplish this goal the Next Generation Nuclear Plant Project (NGNP) has been established by DOE under the Generation IV Nuclear Systems Initiative. Idaho National Laboratory (INL) was designated as the lead in the development of VHTR (Very High Temperature Reactor) and HTGR (High Temperature Gas Reactor) technology to be integrated with MMW (multi-megawatt) helium gas turbine driven electric power AC generators. However, the advantages of transmitting power in high voltage DC form over large distances are also explored in the seminar lecture series. As an attractive alternate heat source the Liquid Fluoride Reactor (LFR), pioneered at ORNL (Oak Ridge National Laboratory) in the mid 1960's, would offer much higher energy yields than current nuclear plants by using an inherently safe energy conversion scheme based on the Thorium --> U233 fuel cycle and a fission process with a negative temperature coefficient of reactivity. The power plants are to be sized to meet electric power demand during peak periods and also for providing thermal energy for hydrogen (H2) production during "off peak" periods. This approach will both supply electric power by using environmentally clean nuclear heat which does not generate green house gases, and also provide a clean fuel H2 for the future, when, due to increased global demand and the decline in discovering new deposits, our supply of liquid fossil fuels will have been used up. This is expected within the next 30 to 50 years, as predicted by the Hubbert model and confirmed by other global energy consumption prognoses. Having invested national resources into the development of NGNP, the technology and experience accumulated during the project needs to be documented clearly and in sufficient detail for young engineers coming on-board at both DOE and NASA to acquire it. Hands on training on reactor operation, test rigs of turbomachinery, and heat exchanger components, as well as computational tools will be needed. Senior scientist/engineers involved with the development of NGNP should also be encouraged to participate as lecturers, instructors, or adjunct professors at local universities having engineering (mechanical, electrical, nuclear/chemical, and/or materials) as one of their fields of study.

Juhasz, Albert J.↗

NASA NTRS2006

An Initial Non-Equilibrium Porous-Media Model for CFD Simulation of Stirling Regenerators

The objective of this paper is to define empirical parameters (or closwre models) for an initial thermai non-equilibrium porous-media model for use in Computational Fluid Dynamics (CFD) codes for simulation of Stirling regenerators. The two CFD codes currently being used at Glenn Research Center (GRC) for Stirling engine modeling are Fluent and CFD-ACE. The porous-media models available in each of these codes are equilibrium models, which assmne that the solid matrix and the fluid are in thermal equilibrium at each spatial location within the porous medium. This is believed to be a poor assumption for the oscillating-flow environment within Stirling regenerators; Stirling 1-D regenerator models, used in Stirling design, we non-equilibrium regenerator models and suggest regenerator matrix and gas average temperatures can differ by several degrees at a given axial location end time during the cycle. A NASA regenerator research grant has been providing experimental and computational results to support definition of various empirical coefficients needed in defining a noa-equilibrium, macroscopic, porous-media model (i.e., to define "closure" relations). The grant effort is being led by Cleveland State University, with subcontractor assistance from the University of Minnesota, Gedeon Associates, and Sunpower, Inc. Friction-factor and heat-transfer correlations based on data taken with the NASAlSunpower oscillating-flow test rig also provide experimentally based correlations that are useful in defining parameters for the porous-media model; these correlations are documented in Gedeon Associates' Sage Stirling-Code Manuals. These sources of experimentally based information were used to define the following terms and parameters needed in the non-equilibrium porous-media model: hydrodynamic dispersion, permeability, inertial coefficient, fluid effective thermal conductivity (including themal dispersion and estimate of tortuosity effects}, and fluid-solid heat transfer coefficient. Solid effective thermal conductivity (including the effect of tortuosity) was also estimated. Determination of the porous-media model parameters was based on planned use in a CFD model of Infinia's Stirling Technology Demonstration Convertor (TDC), which uses a random-fiber regenerator matrix. The non-equilibrium porous-media model presented is considered to be an initial, or "draft," model for possible incorporation in commercial CFD codes, with the expectation that the empirical parameters will likely need to be updated once resulting Stirling CFD model regenerator and engine results have been analyzed. The emphasis of the paper is on use of available data to define empirical parameters (and closure models) needed in a thermal non-equilibrium porous-media model for Stirling regenerator simulation. Such a model has not yet been implemented by the authors or their associates. However, it is anticipated that a thermal non-equilibrium model such as that presented here, when iacorporated in the CFD codes, will improve our ability to accurately model Stirling regenerators with CFD relative to current thermal-equilibrium porous-media models.

Tew, Roy↗

NASA NTRS1979

Aircraft Design Analysis

The helicopter pictured is the twin-turbine S-76, produced by Sikorsky Aircraft division of United Technologies, Stratford, Connecticut. It is the first transport helicopter ever dey n e d purely as a commercial vehicle rather than an adaptation of a military design. Being built in large numbers for customers in 16 countries, the S-76 is intended for offshore oil rig support, executive transportation and general utility service. The craft carries 12 passengers plus a crew of two and has a range of more than 450 miles-yet it weighs less than 10,000 pounds. Significant weight reduction was achieved by use of composite materials, which are generally lighter but stronger than conventional aircraft materials. NASA composite technology played a part in development of the S-76. Under contract with NASA's Langley Research Center, Sikorsky Aircraft designed and flight-tested a helicopter airframe of advanced composite materials.

Source record↗

NASA NTRS2007

Strain Dependence of Photoluminescense of Individual Carbon Nanotubes

We have investigated strain dependence of photoluminescense (PL) spectra of single wall carbon nanotubes (SWNT). Nanotubes were sparsely dispersed in a thin PMMA film applied to acrylic bar, and strained in both compression and extension by bending this bar in either direction in a homebuilt four-point bending rig. The average surface strain was measured with high accuracy by a resistive strain gage applied on top of the film. The near infrared imaging and spectroscopy were performed on the inverted microscope equipped with high numerical aperture reflective objective lens and InGaAs CCD cameras. PL was excited with a diode laser at either 658, 730 or 785 nm, linearly polarized in the direction of the strain. We were able to measure (n,m) types and orientation of individual nanotubes with respect to strain direction and strain dependence of their PL maxima. It was found that PL peak shifts with respect to the values measured in SDS micelles are a sum of three components. First, a small environmental shift due to difference in the dielectric constant of the surrounding media, that is constant and independent of the nanotube type. Second, shift due to isotropic compression of the film during drying. Third, shifts produced by the uniaxial loading of the film in the experiment. Second and third shifts follow expression based on the first-order expansion of the TB hamiltonian. Their magnitude is proportional to the nanotube chiral angle and strain, and direction is determined by the nanotube quantum number. PL strain dependence measured for a number of various nanotube types allows to estimate TB carbon-carbon transfer integral.

Nikolaev, Pavel N.↗

NASA NTRS2007

Investigation of a Parabolic Iterative Solver for Three-dimensional Configurations

A parabolic iterative solution procedure is investigated that seeks to extend the parabolic approximation used within the internal propagation module of the duct noise propagation and radiation code CDUCT-LaRC. The governing convected Helmholtz equation is split into a set of coupled equations governing propagation in the positive and negative directions. The proposed method utilizes an iterative procedure to solve the coupled equations in an attempt to account for possible reflections from internal bifurcations, impedance discontinuities, and duct terminations. A geometry consistent with the NASA Langley Curved Duct Test Rig is considered and the effects of acoustic treatment and non-anechoic termination are included. Two numerical implementations are studied and preliminary results indicate that improved accuracy in predicted amplitude and phase can be obtained for modes at a cut-off ratio of 1.7. Further predictions for modes at a cut-off ratio of 1.1 show improvement in predicted phase at the expense of increased amplitude error. Possible methods of improvement are suggested based on analytic and numerical analysis. It is hoped that coupling the parabolic iterative approach with less efficient, high fidelity finite element approaches will ultimately provide the capability to perform efficient, higher fidelity acoustic calculations within complex 3-D geometries for impedance eduction and noise propagation and radiation predictions.

Nark, Douglas M.↗

NASA NTRS2007

A New Method for Breath Capture Inside a Space Suit Helmet

This project investigates methods to capture an astronaut's exhaled carbon dioxide (CO2) before it becomes diluted with the high volumetric oxygen flow present within a space suit. Typical expired breath contains CO2 partial pressures (pCO2) in the range of 20-35 mm Hg. This research investigates methods to capture the concentrated CO2 gas stream prior to its dilution with the low pCO2 ventilation flow. Specifically this research is looking at potential designs for a collection cup for use inside the space suit helmet. The collection cup concept is not the same as a breathing mask typical of that worn by firefighters and pilots. It is well known that most members of the astronaut corps view a mask as a serious deficiency in any space suit helmet design. Instead, the collection cup is a non-contact device that will be designed using a detailed Computational Fluid Dynamic (CFD) analysis of the ventilation flow environment within the helmet. The CFD code, Fluent, provides modeling of the various gas species (CO2, water vapor, and oxygen (O2)) as they pass through a helmet. This same model will be used to numerically evaluate several different collection cup designs for this same CO2 segregation effort. A new test rig will be built to test the results of the CFD analyses and validate the collection cup designs. This paper outlines the initial results and future plans of this work.

Filburn, Tom↗

NASA NTRS2007

Tribological Performance of PM300 Solid Lubricant Bushings for High Temperature Applications

PM300 is a high temperature solid lubricant material produced through conventional powder metallurgy processing. PM300 is a combination of metal binder (NiCr), hardener (Cr2O3) and lubricant (Ag and BaF2/CaF2) phases and is in commercial use in high temperature furnace conveyors. In this paper, the tribological characteristics of PM300 are evaluated using a newly developed bushing test rig in which PM300 bushings are loaded against rotating steel shafts at temperatures from 25 to 650 C. The data shows that friction and wear are low to moderate and that the lubrication performance (friction) improves with increasing temperature. Several alternative PM300 compositions are evaluated which do not contain silver and are targeted at aircraft gas turbine applications in which environmental compatibility of silver is a concern. It is expected that the data resulting from this research will further the commercialization of this technology.

Striebing, Donald R.↗