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NASA NTRS2026

Turbofan Engine Power Extraction Demonstration Final Report

As GE Aerospace advances toward a revolutionary step change in propulsion efficiency, the integration and demonstration of new engine architectures and technology systems are essential. The NASA Turbofan Engine Power Extraction Demonstration (PEx), conducted through the Hybrid Thermally Efficient Core (HyTEC) project, aims to develop and demonstrate megawatt-class hybrid electric capability on a modern commercial turbofan engine. The hybrid electric system is critical to meeting the needs of the U.S. aviation industry for next-generational propulsion systems with greater efficiency, durability, and range. This supports energy independence and helps ensure the security and resilience of one of America's largest export industries. The PEx project specifically targets three key objectives: mechanically integrating hybrid electric capability into a commercial turbofan engine, integrating electric machine control with turbofan control for advanced power management, and de-risking performance modeling of future hybrid electric architectures. To mature these technologies to Technology Readiness Level (TRL) 6, a series of electric power system component tests and a baseline engine performance test campaign were conducted. These efforts culminated in an integrated hybrid electric turbofan test campaign demonstrating power extraction, power insertion, and power transfer between spools. Tests of the electric power system were completed at GE Aerospace’s Electrical Power Integrated Systems Center in Dayton, Ohio and engine tests were completed at Peebles Test Operation in Peebles, Ohio. Hybrid electric trade studies extended the demonstrated capability to altitude using the validated cycle model from the PEx test campaigns, allowing for comments on expanded mission benefits not demonstrated in the ground campaign. The knowledge gained from PEx also supports GE Aerospace’s Compact Core Demonstrator as part of HyTEC Phase 2 and ultimately informs the implementation of hybrid electric systems in the next generation of GE Aerospace commercial engine products. This report provides a summary of the program background, test campaigns, trade studies, and insights into the technical maturation required to support future commercial products.

Hybrid Electric↗

NASA NTRS2024

Hybrid Thermally Efficient Core (HyTEC) HyTEC Phase 1 – Advanced Aerodynamics Final Report

The objective of the Hybrid Thermally Efficient Core (HyTEC) – Advanced High Pressure Turbine (HPT) Aerodynamics project is to develop technology for a compact core that contributes to significant fuel burn reductions of 5-10% over current generation technologies. To accomplish this, the HPT is incorporating a range of aerodynamic features and technologies to improve component efficiency and provide favorable systems level trades. In particular, this project explored low solidity airfoils, advanced tip treatments, platform contouring, and advanced ceramic matrix composite (CMC) Stage 2 Nozzle (S2N) airfoils to eliminate the need for post throat cooling in a compact core environment. The maturation of these technology areas is expected to provide a significant improvement in component efficiencies, and consequently reductions in fuel burn, over the current state of the art (SoA). To mature these technologies to Technology Readiness Level (TRL) 4, a test campaign was performed that consisted of four tests at three facilities. TRL 3 testing was performed in the CW22 linear cascade at NASA Glenn for blade and nozzle technologies, TRL 4 nozzle testing was performed at GE Aerospace (GEA) Test Cell A8, and TRL 4 blade testing was performed at the Notre Dame Turbomachinery Laboratory (NDTL) using the Transonic Research Turbine (TRT) rig. Low solidity was successfully demonstrated to a TRL 4 level. Low solidity nozzles showed benefits in line with pre-project expectations, while low solidity blades were shown to have an aerodynamic penalty. Crucially, this program only considered the aerodynamic losses, and systems trades such as reductions in cooling flows are expected to continue to make low solidity blades a net positive. By successfully quantifying the aerodynamic performance in this project, these trades can be conducted to determine where in the engine architecture low solidity blades will contribute positively to system operation. Platform contouring was demonstrated to a TRL 4 level, with performance in line with the lower end of the pre-project expected range. Advanced tip treatments performance levels were indeterminate, showing the expected improvements to flow physics but with a performance level confounded by several rig issues including whirl mode induced variation in tip clearance. The elimination of post-throat cooling on the S2N was successfully demonstrated to provide a performance benefit, however that benefit was approximately half the level that was expected in pre-project predictions. Overall, the technology maturation plan for HyTEC Phase 1 was successful, bringing the suite of technologies to TRL 4.

High pressure turbine↗

NASA NTRS2026

NASA Hybrid Thermally Efficient Core (HyTEC) Phase 2 Q3’GFY25 to Q2’GFY26 Unlimited Rights Annual Report for CLIN 1 and 2

The HyTEC Phase 2 Project focuses on the development and demonstration of high-power density, small engine core gas turbine engine technologies. The focus of HyTEC on these small engine core technologies will provide direct benefits to the next single-aisle class aircraft in terms of thermal efficiency, as well as integrate with other technologies, through increased hybridization, as they mature to provide substantial continuous fuel burn reductions during the aircraft lifecycle. These advances will strengthen the US position in the commercial aviation engine market and enable cost benefits in commercial aviation. In Government fiscal year 26 the HyTEC Project was closed and contract moved to the Subsonic Vehicle Technologies and Tools Project. GE Aerospace is executing two major work plans as part of the HyTEC Phase 2 contract. The first is Contract Line-Item Number (CLIN) 001 and its objective is to mature High Pressure Turbine (HPT) aerodynamics technology to TRL 5 through multiple rigs so that it may be incorporated into a complete TRL 6 evaluation and unlock learnings for the engine core demonstration as applicable. CLIN 002, the second work plan, is to design, procure and test a cost shared portion of technologies on the TRL6 Compact Core test vehicle. The compact core demonstrated through HyTEC Phase 2 along with the HPT rig TRL advancement directly matures the technologies being developed as part of the CFM RISE demonstrator program which is targeting a more than 20% fuel burn reduction at the engine level versus today’s state of the art. The RISE program’s objective is to advance both the novel Open Fan architecture, compact core technologies and advanced systems such as hybrid electric needed to achieve the desired fuel burn reduction to TRL6 ahead of a new product introduction in the single-aisle class aircraft in the 2030s timeframe.

gas turbine engine↗

NASA NTRS2011

Effect of Environmental Exposures on Fatigue Life of P/M Disk Superalloys

As the temperature capability of Ni-base superalloy powder metallurgy disks is steadily increased, environmental resistance and protection of advanced nickel-based turbine disk components are becoming increasingly important. Localized surface hot corrosion attack and damage from oxidation have been shown to impair disk fatigue life and may eventually limit disk operating temperatures. NASA Research Announcement (NRA) contracts have been awarded to GE Aviation and Honeywell Aerospace to separately develop fatigue resistant metallic and ceramic coatings for corrosion resistance and the corrosion/fatigue results of selected coatings will be presented. The microstructural response of a bare ME3 disk superalloy has been evaluated for moderate (704 C) and aggressive (760-816 C) oxidizing exposures up to 2,020 hours. Cross section analysis reveals sub-surface damage (significant for aggressive exposures) that consists of Al2O3 "fingers", interfacial voids, a recrystallized precipitate-free layer and GB carbide dissolution. The effects of a Nichrome corrosion coating on this microstructural response will also be presented.

Draper, Susan↗

NASA NTRS1989

Space biology initiative program definition review. Trade study 5: Modification of existing hardware (COTS) versus new hardware build cost analysis

The JSC Life Sciences Project Division has been directly supporting NASA Headquarters, Life Sciences Division, in the preparation of data from JSC and ARC to assist in defining the Space Biology Initiative (SBI). GE Government Services and Horizon Aerospace have provided contract support for the development and integration of review data, reports, presentations, and detailed supporting data. An SBI Definition (Non-Advocate) Review at NASA Headquarters, Code B, has been scheduled for the June-July 1989 time period. In a previous NASA Headquarters review, NASA determined that additional supporting data would be beneficial to determine the potential advantages in modifying commercial off-the-shelf (COTS) hardware for some SBI hardware items. In order to meet the demands of program implementation planning with the definition review in late spring of 1989, the definition trade study analysis must be adjusted in scope and schedule to be complete for the SBI Definition (Non-Advocate) Review. The relative costs of modifying existing commercial off-the-shelf (COTS) hardware is compared to fabricating new hardware. An historical basis for new build versus modifying COTS to meet current NMI specifications for manned space flight hardware is surveyed and identified. Selected SBI hardware are identified as potential candidates for off-the-shelf modification and statistical estimates on the relative cost of modifying COTS versus new build are provided.

Jackson, L. Neal↗

NASA NTRS2014

Identification of Vehicle Health Assurance Related Trends

Trend analysis in aviation as related to vehicle health management (VHM) was performed by reviewing the most current statistical and prognostics data available from the National Transportation Safety Board (NTSB) accident, the Federal Aviation Administration (FAA) incident, and the NASA Aviation Safety Reporting System (ASRS) incident datasets. In addition, future directions in aviation technology related to VHM research areas were assessed through the Commercial Aviation Safety Team (CAST) Safety Enhancements Reserved for Future Implementations (SERFIs), the National Transportation Safety Board (NTSB) Most-Wanted List and recent open safety recommendations, the National Research Council (NRC) Decadal Survey of Civil Aeronautics, and the Future Aviation Safety Team (FAST) areas of change. Future research direction in the VHM research areas is evidently strong as seen from recent research solicitations from the Naval Air Systems Command (NAVAIR), and VHM-related technologies actively being developed by aviation industry leaders, including GE, Boeing, Airbus, and UTC Aerospace Systems. Given the highly complex VHM systems, modifications can be made in the future so that the Vehicle Systems Safety Technology Project (VSST) technical challenges address inadequate maintenance crew's trainings and skills, and the certification methods of such systems as recommended by the NTSB, NRC, and FAST areas of change.

Phojanamongkolkij, Nipa↗

NASA NTRS1987

Communications payload concepts for geostationary facilities

Summarized and compared are the major results of two NASA sponsored studies that defined potential communication payload concepts to meet the satellite traffic forecast for the turn of the century for the continental US and Region 2 of the International Telecommunications Union. The studies were performed by the Ford Aerospace and Communications Corporation and RCA Astro-Electronics (now GE-RCA Astro-Space Division). Future scenarios of aggregations of communications services are presented. Payload concepts are developed and defined in detail for nine of the scenarios. Payload costs and critical technologies per payload are also presented. Finally the payload concepts are compared and the findings of the reports are discussed.

Poley, William A.↗

NASA NTRS1983

Low background IR detector and detector array evaluations

A technology program has been underway at Ames since 1978 to develop and evaluate detectors and integrated detector arrays for low-background astronomical applications. The approach is to evaluate existing (less than 24 micron) array technology under low-background conditions, with the aim of adapting and optimizing existing devices. For longer wavelengths, where the technology is much less mature, development is sponsored and devices are evaluated, in both discrete and array formats, for eventual applications. The status of this program has been reported previously. We rely on industrial and university sources for the detectors. Typically, after a brief functionality check in the supplier's laboratory, we work with the device at Ames to characterize its low-background performance. In the case of promising arrays or detectors, we conduct ground-based telescope testing to face the problems associated with real applications. A list of devices tested at Ames is given. In the array category, accumulation-mode charge-injection-devices (AMCIDs) appear repeatedly; this reflects our recent experience with the 2 x 64 and 16 x 16 arrays. Results from the 1 x 16 CID and InSb CCD have been reported. The status of our tests of the discrete Ge:x detectors from Lawrence Berkeley Laboratory are described below. Tests of a 1 x 2 switched sample photoconductor array are just beginning. A 32-channel CMOS multiplexer has been tested at 10 K. Low-temperature silicon MOSFETs and germanium JFETs have also been tested, primarily at Ball Aerospace. This paper describes results to date on three elements of this program: AMCID array, discrete Ge:Ga detectors, and Ge JFET preamplifiers.

Goebel, J. H.↗

NASA NTRS1988

Pyro shock simulation: Experience with the MIPS simulator

The Mechanical Impulse Pyro Shock (MIPS) Simulator at GE Astro Space Division is one version of a design that is in limited use throughout the aerospace industry, and is typically used for component shock testing at levels up to 10,000 response g's. Modifications to the force imput, table and component boundary conditions have allowed a range of test conditions to be achieved. Twelve different designs of components with weights up to 23 Kg are in the process or have completed qualification testing in the Dynamic Simulation Lab at GE in Valley Forge, Pa. A summary of the experience gained through the use of this simulator is presented as well as examples of shock experiments that can be readily simulated at the GE Astro MIPS facility.

Dwyer, Thomas J.↗

NASA NTRS1999

Resistance of Titanium Aluminide to Domestic Object Damage Assessed

A team consisting of GE Aircraft Engines, Precision Cast Parts, Oremet, and Chromalloy were awarded a NASA-sponsored Aerospace Industry Technology Program (AITP) to develop a design and manufacturing capability that will lead to the engine test demonstration and eventual implementation of a ?-Ti-47Al-2Nb-2Cr (at. %) titanium aluminide (TiAl) low-pressure turbine blade into commercial service. One of the main technical risks of implementing TiAl low-pressure turbine blades is the poor impact resistance of TiAl in comparison to the currently used nickel-based superalloy. The impact resistance of TiAl is being investigated at the NASA Lewis Research Center as part of the Aerospace Industry Technology Program and the Advanced High Temperature Engine Materials Program (HITEMP). The overall objective of this work is to determine the influence of impact damage on the high cycle fatigue life of TiAl-simulated low-pressure turbine blades. To this end, impact specimens were cast to size in a dog-bone configuration and given a typical processing sequence followed by an exposure to 650 degrees Celsius for 20 hours to simulate embrittlement at service conditions. Then, the specimens were impacted at 260 degrees Celsius under a 69-MPa load. Steel projectiles with diameters 1.6 and 3.2 mm were used to impact the specimens at 90 degrees Celsius to the leading edge. Two different impact energies (0.74 and 1.5 joules) were used to simulate fairly severe domestic object damage on a low-pressure turbine blade.

Lerch, Bradley A.↗

NASA NTRS1986

Qualification Testing of General Electric 50 Ah Nickel-Cadmium Cells with New Separator and New Positive Plate Processing

Forty-two 50 Ah aerospace nickel-cadmium cells were delivered to Goddard Space Flight Center (GSFC) by General Electric (GE) in February, 1985, for the purpose of evaluating and qualifying a new nylon separator material Pellon 2536, and the new GE Positive Plate Nickel Attack Control Passivation process. Testing began in May, 1985, at the Naval Weapons Support Center (NWSC) in Crane, Indiana with standard initial evaluation tests. Life cycling in both Low Earth Orbit (LEO) and Geosynchronous Orbit (GEO) began in July, 1985, with approximately 1200 LEO cycles complete at this writting. Early test results show that cells with positive plate passivation exhibit higher than normal charge voltage characteristics. Other aspects of performance were nominal.

Morrow, G. W.↗

NASA NTRS2016

NASA Phase2 Unlimited Rights Final Report Research and Technology for Aerospace Propulsion Systems (RTAPS) Task Order: ERA Advanced Core Compressor Technology Program

As part of the NASA Integrated Systems Research Program (ISRP), Environmentally Responsible Aviation (ERA) Project, NASA GRC and GE Aviation have partnered to investigate the technology barriers associated with improved fuel economy of large gas turbine engines. Crucial to improving fuel economy is the increase in pressure ratio (PR) of the core high pressure compressor (HPC). A key enabler to increasing HPC pressure ratios are new technology front stage airfoil designs that have higher efficiency, higher pressure ratios and improvements in front stage part-power operability. The purpose of this work is to design and test two high pressure ratio, high efficiency front block designs. The baseline design, hereafter referred to as Build 1, is similar to what would be found in a high efficiency 30:1 PR class HPC. A redesigned front block with improved blading will also be tested and hereafter be referred to as Build 2. The goal of Build 2 is to increase stage aero loading (increase stage pressure ratio) beyond Build 1 while maintaining equivalent efficiency and stall margin. The detailed inter-stage and traverse data from the two builds will be used to improve understanding of the complex flow physics at high-speed and part-speed conditions that impact performance and operability. By addressing, understanding and solving the challenges associated with aerodynamic losses and stage matching better design strategies can be incorporated in future core compressors with higher efficiency, thereby enabling improvement in mission fuel burn while still meeting operability requirements.

Axial Compressors↗

NASA NTRS2004

Improving the Flow

In early 1995, NASA s Glenn Research Center (then Lewis Research Center) formed an industry-government team with several jet engine companies to develop the National Combustion Code (NCC), which would help aerospace engineers solve complex aerodynamics and combustion problems in gas turbine, rocket, and hypersonic engines. The original development team consisted of Allison Engine Company (now Rolls-Royce Allison), CFD Research Corporation, GE Aircraft Engines, Pratt and Whitney, and NASA. After the baseline beta version was established in July 1998, the team focused its efforts on consolidation, streamlining, and integration, as well as enhancement, evaluation, validation, and application. These activities, mainly conducted at NASA Glenn, led to the completion of NCC version 1.0 in October 2000. NCC version 1.0 features high-fidelity representation of complex geometry, advanced models for two-phase turbulent combustion, and massively parallel computing. Researchers and engineers at Glenn have been using NCC to provide analysis and design support for various aerospace propulsion technology development projects. NASA transfers NCC technology to external customers using non- exclusive Space Act Agreements. Glenn researchers also communicate research and development results derived from NCC's further development through publications and special sessions at technical conferences.

Source record↗

NASA NTRS1995

NASA-UVA Light Aerospace Alloy and Structures Technology program (LA2ST)

The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The general aim is to produce relevant data and basic understanding of material mechanical response, environment/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated students for aerospace technologies. Specific technical objectives are presented for each of the following research projects: time-temperature dependent fracture in advanced wrought ingot metallurgy, and spray deposited aluminum alloys; cryogenic temperature effects on the deformation and fracture of Al-Li-Cu-In alloys; effects of aging and temperature on the ductile fracture of AA2095 and AA2195; mechanisms of localized corrosion in alloys 2090 and 2095; hydrogen interactions in aluminum-lithium alloys 2090 and selected model alloys; mechanisms of deformation and fracture in high strength titanium alloys (effects of temperature and hydrogen and effects of temperature and microstructure); evaluations of wide-panel aluminum alloy extrusions; Al-Si-Ge alloy development; effects of texture and precipitates on mechanical property anisotropy of Al-Cu-Mg-X alloys; damage evolution in polymeric composites; and environmental effects in fatigue life prediction - modeling crack propagation in light aerospace alloys.

Starke, Edgar A., Jr.↗

NASA NTRS2002

NPSS Overview to TAFW Multidisciplinary Simulation Capabilities

The Numerical Propulsion System Simulation (NPSS) is a concerted effort by NASA Glenn Research Center, the aerospace industry, and academia to develop an advanced engineering environment or integrated collection of software programs for the analysis and design of aircraft engines and, eventually, space transportation components. NPSS is now being applied by GE ground power to ground power generation with the view of expanding the capability to nontraditional power plant applications (example: fuel cells) and NPSS has an interest in in-space power and will be developing those simulation capabilities.

Owen, Karl↗

NASA NTRS1990

Thermal balance testing of the Anik-E spacecraft

Spar Aerospace, Ltd. of Canada has recently completed the first of two infrared thermal balance/thermal vacuum tests on Canada's next generation of telecommunication satellites: Anik-E. Anik-E is a two spacecraft program using a three axis stabilized GE 5000 series bus as the vehicle for its payload. The infrared test setup consists of the mechanical hardware required to support the spacecraft within the thermal vacuum chamber and the infrared rig which supports the spacecraft. Spar developed a software package which calculated the lamp positions to provide the necessary uniform heat flux, based on the required heat inputs on the various isothermal zones of the spacecraft for the different phases of the tests. Infrared heat sensors, radiometers, were installed on the spacecraft surfaces. These were connected to the facility data processing system and continually monitored the flux absorbed by the various spacecraft surfaces. The test set up had distinct advantages. It enabled testing to progress directly from the thermal balance to thermal vacuum. Waveguide runs were installed for the communications portion of the testing prior to pumpdown. This precluded the requirement to return to ambient to reconfigure the setup.

Golob, Alex↗

NASA NTRS2003

CORBASec Used to Secure Distributed Aerospace Propulsion Simulations

The NASA Glenn Research Center and its industry partners are developing a Common Object Request Broker (CORBA) Security (CORBASec) test bed to secure their distributed aerospace propulsion simulations. Glenn has been working with its aerospace propulsion industry partners to deploy the Numerical Propulsion System Simulation (NPSS) object-based technology. NPSS is a program focused on reducing the cost and time in developing aerospace propulsion engines. It was developed by Glenn and is being managed by the NASA Ames Research Center as the lead center reporting directly to NASA Headquarters' Aerospace Technology Enterprise. Glenn is an active domain member of the Object Management Group: an open membership, not-for-profit consortium that produces and manages computer industry specifications (i.e., CORBA) for interoperable enterprise applications. When NPSS is deployed, it will assemble a distributed aerospace propulsion simulation scenario from proprietary analytical CORBA servers and execute them with security afforded by the CORBASec implementation. The NPSS CORBASec test bed was initially developed with the TPBroker Security Service product (Hitachi Computer Products (America), Inc., Waltham, MA) using the Object Request Broker (ORB), which is based on the TPBroker Basic Object Adaptor, and using NPSS software across different firewall products. The test bed has been migrated to the Portable Object Adaptor architecture using the Hitachi Security Service product based on the VisiBroker 4.x ORB (Borland, Scotts Valley, CA) and on the Orbix 2000 ORB (Dublin, Ireland, with U.S. headquarters in Waltham, MA). Glenn, GE Aircraft Engines, and Pratt & Whitney Aircraft are the initial industry partners contributing to the NPSS CORBASec test bed. The test bed uses Security SecurID (RSA Security Inc., Bedford, MA) two-factor token-based authentication together with Hitachi Security Service digital-certificate-based authentication to validate the various NPSS users. The test bed is expected to demonstrate NPSS CORBASec-specific policy functionality, confirm adequate performance, and validate the required Internet configuration in a distributed collaborative aerospace propulsion environment.

Blaser, Tammy M.↗

NASA NTRS1985

Results of Analysis on the Design Variable Cells

Sealed Nickel-Cadmium aerospace cells play a very important role in the mission of the satellite. There has been a constant effort to improve the cycle life, energy density, and reliability of these cells by many manufacturers and users. The Design Variable Cell Program is one systematic approach started by NASA in collaboration with General Electric (GE) towards that goal. Nine important designs were selected for evaluation. Fifty-two nickel-cadmium cells each of 12 Ah nominal capacity manufactured by GE were sent to the Navel weapons Support Center for evaluation of different design variables with which these cells were built.

Vasanth, K. L.↗