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The selection procedure is described which was used to arrive at the configurations tested, and the performance characteristics of the test nozzles are given.
This paper reports initial results from an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) missions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water.
The acoustic characteristics of the double annular combustor in a CF6-50 high bypass turbofan engine were investigated. Internal fluctuating pressure measurements were made in the combustor region and in the core exhaust. The transmission loss across the turbine and nozzle was determined from the measurements and compared to previous component results and present theory. The primary noise source location in the combustor was investigated. Spectral comparisons of test rig results were made with the engine results. The measured overall power level was compared with component and engine correlating parameters.
A control system for a turbofan engine receives signals from a number of engine sensors and from the engine operator, and generates control signals. One control signal regulates the fan exhaust nozzle area in order to control inlet throat Mach number to maintain a low level of engine noise. Additional control signals regulate fuel flow to control engine thrust and fan pitch to control fan speed. A number of schedules are utilized to maintain a predetermined relationship between the controlled parameters and a number of fixed and calculated limits can override the control signals to prevent unsatisfactory engine performance.
An experimental investigation of the high speed aerodynamics of Upper Surface Blowing (USB) aircraft configurations has been conducted to accurately define the magnitude and causes of the powered configuration cruise drag. A highly instrumented wind tunnel model of a realistic USB configuration was used which permitted parametric variations in the number and spanwise location of the nacelles and was powered with two turbofan engine simulators. The tests conducted in the Ames 14 Foot Transonic Wind Tunnel examined 10 different configurations at Mach numbers from 0.5 to 0.775, fan nozzle pressure ratios from 1.1 to 2.1 and angles of attack from -4 to 6 degrees. Measured force data is presented which indicates the cruise drag penalty associated with each configuration and surface pressure contour plots are used to illustrate the underlying flowfield physics. It was found that all of the tested configurations suffered from a severe drag penalty which increased with freestream Mach number, power setting and angle of attack and was associated with the presence of strong shocks and regions of separated flow in the wing/nacelle junction regions.
An exhaust-gas pressure and temperature survey of the General Electric F404-GE-400 turbofan engine was conducted in the altitude test facility of the NASA Lewis Propulsion System Laboratory. Traversals by a survey rake were made across the exhaust-nozzle exit to measure the pitot pressure and total temperature. Tests were performed at Mach 0.87 and a 24,000-ft altitude and at Mach 0.30 and a 30,000-ft altitude with various power settings from intermediate to maximum afterburning. Data yielded smooth pressure and temperature profiles with maximum jet temperatures approximately 1.4 in. inside the nozzle edge and maximum jet temperatures from 1 to 3 in. inside the edge. A low-pressure region located exactly at engine center was noted. The maximum temperature encountered was 3800 R.
Program uses component performance maps to enable user to do analytical engine cycle calculations. Through scaling procedure, each of the component maps can be used to represent a family of maps. Either convergent or convergent-divergent nozzles may be used.
A JT8D-17 turbofan engine was tested in a 40 x 80 ft wind tunnel to determine flight effects on jet noise. The engine was configured as a baseline with conical nozzle, a quiet nacelle 20-lobe ejector/suppressor, and an internal mixer with conical nozzle. Tunnel-off and tunnel-on noise tests were conducted over a range of nozzle pressure ratios (1.2 to 2.1), primary jet velocities (275 to 550 m/s), and tunnel velocities up to 100 m/s. Aft quadrant noise data were measured by a pair of traversing microphones located on a 3-m sideline relative to the engine centerline. Unique correlations and analysis procedures were developed in order to define far-field flight effects from the relatively near-field noise measurements. The ejector/suppressor experienced a significant loss of suppression relative to static measurements during flight while the internal mixer indicated a slight gain in suppression. It is concluded that the wind tunnel is a viable method for studying flight effects on engine jet noise.
A series of experiments was carried out in order to produce design data for a premixing prevaporizing fuel-air mixture preparation system for aircraft gas turbine engine combustors. The fuel-air mixture uniformity of four different system design concepts was evaluated over a range of conditions representing the cruise operation of a modern commercial turbofan engine. Operating conditions including pressure, temperature, fuel-to-air ratio, and velocity, exhibited no clear effect on mixture uniformity of systems using pressure-atomizing fuel nozzles and large-scale mixing devices. However, the performance of systems using atomizing fuel nozzles and large-scale mixing devices was found to be sensitive to operating conditions. Variations in system design variables were also evaluated and correlated. Mixing uniformity was found to improve with system length, pressure drop, and the number of fuel injection points per unit area. A premixing system capable of providing mixing uniformity to within 15 percent over a typical range of cruise operating conditions is demonstrated.
The papers in this volume reflect the progress in aeroacoustic research which has been made in the field of VTOL and V/STOL aircraft noise. The research was directed mainly at developing better methods for predicting noise generation and propagation, at determining the effects of pressure fluctuations on surfaces and interior noise, and at developing noise abatement techniques. Among the topics covered are: scrubbing noise of externally blown flaps; propulsive-lift noise of an upper-surface-blown flap configuration; the aeroacoustic characteristics of model slot nozzles with straight flaps; fluctuating pressures on aircraft wing and flap surfaces associated with powered-lift systems; acoustic characteristics of a large upper-surface-blown configuration with turbofan engines; the effect of forward speed on jet/flap interaction noise; and airframe noise in the far field.
As part of the Advanced Subsonic Technology Program, a series of experiments was conducted at NASA Glenn Research Center on the effect of mixing enhancement devices on the aeroacoustic performance of separate flow nozzles. Initial acoustic evaluations of the devices showed that they reduced jet noise significantly, while creating very little thrust loss. The explanation for the improvement required that turbulence measurements, namely single point mean and RMS statistics and two-point spatial correlations, be made to determine the change in the turbulence caused by the mixing enhancement devices that lead to the noise reduction. These measurements were made in the summer of 2000 in a test program called Separate Nozzle Flow Test 2000 (SFNT2K) supported by the Aeropropulsion Research Program at NASA Glenn Research Center. Given the hot high-speed flows representative of a contemporary bypass ratio 5 turbofan engine, unsteady flow field measurements required the use of an optical measurement method. To achieve the spatial correlations, the Particle Image Velocimetry technique was employed, acquiring high-density velocity maps of the flows from which the required statistics could be derived. This was the first successful use of this technique for such flows, and shows the utility of this technique for future experimental programs. The extensive statistics obtained were likewise unique and give great insight into the turbulence which produces noise and how the turbulence can be modified to reduce jet noise.
The investigation utilizing a small turbofan engine was conducted to evaluate static turning performance and pressure and temperature environment of an upper surface blown wing and flap segment. The tests involved modifications of the engine primary nozzle to alleviate high-temperature problems on the wing and flaps without adversely affecting static turning performance over the desired range of flap deflection and thrust condition.
The standard hydromechanical control modes for TF30-P-3 engine were implemented on a digital process control computer. Programming methods are described, and a method is presented to solve stability problems associated with fast response dynamic loops contained within the exhaust nozzle control. A modification of the exhaust nozzle control to provide for either velocity or position servoactuation systems is discussed. Transient response of the digital control was evaluated by tests on a real time hybrid simulation of the TF30-P-3 engine. It is shown that the deadtime produced by the calculation time delay between sampling and final output is more significant to transient response than the effects associated with sampling rate alone. For the main fuel control, extended update and calculation times resulted in a lengthened transient response to throttle bursts from idle to intermediate with an increase in high pressure compressor stall margin. Extremely long update intervals of 250 msec could be achieved without instability. Update extension for the exhaust nozzle control resulted in a delayed response of the afterburner light-off detector and exhaust nozzle overshoot with resulting fan oversuppression. Long update times of 150 msec caused failure of the control due to a false indication by the blowout detector.
Rolls-Royce North American Technologies, Inc. (LibertyWorksLW) began considering the development of CMC exhaust forced mixers in 2008, as a means of obtaining reduced weight and hotter operating temperature capability, while minimizing shape distortion during operation, which would improve mixing efficiency and reduce fuel burn. Increased component durability, enhanced ability to fabricate complex-shaped components, and engine noise reduction are other potential advantages of CMC mixers (compared to metallic mixers). In 2010, NASA was pursuing the reduction of NOx emissions, fuel burn, and noise from turbine engines in Phase I of the Environmentally Responsible Aviation (ERA) Project. ERA subtasks, including those focused on CMC components, were formulated with the goal of maturing technology from proof of concept validation (TRL 3) to a systemsubsystem or prototype demonstration in a relevant environment (TRL 6). In April 2010, the NASA Glenn Research Center (GRC) and LibertyWorks jointly initiated a CMC Exhaust System Validation Program within the ERA Project, teaming on CMC exhaust mixer development for subsonic jet engines capable of operating with increased performance. Our initial focus was on designing, fabricating, and characterizing the thrust and acoustic performance of a roughly quarter-scale 16-lobe oxide oxide CMC mixer and tail cone along with a conventional low bypass exhaust nozzle. Support Services, LLC (Allendale, MI) and ATK COI Ceramics, Inc. (COIC, in San Diego, CA) supported the design of a subscale nozzle assembly that consisted of an oxide oxide CMC mixer and center body, with each component mounted on a metallic attachment ring. That design was based upon the operating conditions a mixer would experience in a turbofan engine. Validation of the aerodynamic and acoustic performance of the subscale mixer via testing and the achievement of TRL 4 encouraged the NASALWCOIC team to move to the next phase where a full scale CMC mixer sized for a RR AE3007 engine and a compatible attachment flange were designed, followed by CMC component fabrication by COIC, and vibration testing at GRC under conditions simulating the structural and dynamic environment encountered during engine operation. AFRL (WPAFB) supported this testing by performing 3D laser vibrometry to identify the mixer mode shapes and modal frequencies. The successful fabrication and testing of such a component has been achieved. The CMC mixer demonstrated good durability during vibration testing at room and elevated temperature (TRL5). This has cleared the article for a ground-based test on a Rolls-Royce AE3007 engine, where the performance and benefits of the component can be further assessed.
The performance of a YF-102 turbofan engine was measured in an outdoor test stand with a bellmouth inlet and seven exhaust-system configurations. The configurations consisted of three separate-flow systems of various fan and core nozzle sizes and four confluent-flow systems of various nozzle sizes and shapes. A computer program provided good estimates of the engine performance and of thrust at maximum rating for each exhaust configuration. The internal performance of two different-shaped core nozzles for confluent-flow configurations was determined to be satisfactory. Pressure and temperature surveys were made with a traversing probe in the exhaust-nozzle flow for some confluent-flow configurations. The survey data at the mixing plane, plus the measured flow rates, were used to calculate the static-pressure variation along the exhaust nozzle length. The computed pressures compared well with experimental wall static-pressure data. External-flow surveys were made, for some confluent-flow configurations, with a large fixed rake at various locations in the exhaust plume.
In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $ \$ $6B annually (at $ \$ $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year), and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE) missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.
In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.
New developments and refinements in measuring techniques used for both ground testing and in-flight control, diagnosis, and monitoring of airbreathing combustors are analyzed in a number of papers. Some of the techniques studied include the application of laser velocimeters for flow measurements; on-the-shaft data systems for rotating engine components; total pressure averaging in pulsating flows; fiber optic and laser digital pressure transducers; holography of nozzles, jets, and spraying systems; application of the Raman effect fo flowfield diagnostics; holography of JP-4 droplets and combusting boron particles; the use of a laser-powered optical proximity probe in advanced turbofan engine development; pyrometry for measurement of surface temperature distribution on a rotating turbine blade; an ultrasonic turbine inlet gas temperature sensor; automatic detection and suppression of inlet buzz; and electrostatic probes for sensing incipient engine failure. Individual items are announced in this issue.