ALBERT

Description: Both the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) have worked to develop and demonstrate erosion-resistant coatings that would increase the life and durability of composite materials used in commercial aircraft engines. These composite materials reduce component weight by 20 to 30 percent and result in less fuel burn and emissions and more fuel savings. Previously, however, their use was limited because of poor erosion resistance, which causes concerns about safety and leads to high maintenance costs. The coatings were tested by the University of Cincinnati, and the composites were manufactured by Texas Composites and coated by Engelhard and NASA Glenn. Rolls-Royce Corporation uses composite materials, which are stronger and less dense than steel or titanium, to make bypass vanes for their AE3007 engines. These engines are widely used in regional jet aircraft (Embraer) and unmanned air vehicles such as the Northrop Grumman Global Hawk. Coatings developed by NASA/Rolls-Royce can reduce erosion from abrasive materials and from impurities in the air that pass over these vanes, allowing Rolls-Royce to take advantage of the benefits of composite materials over titanium without the added costs of increased maintenance and/or engine failure. The Higher Operating Temperature Propulsion Components (HOTPC) Project developed cost-effective, durable coatings as part of NASA's goal to increase aviation system capacity growth. These erosion coatings will reduce the number of special inspections or instances of discontinued service due to erosion, allowing aircraft capacity to be maintained without inconveniencing the traveling public. A specific example of extending component life showed that these coatings increased the life of graphite fiber and polymer composite bypass vanes up to 8 times over that of the uncoated vanes. This increased durability allows components to operate to full design life without the fear of wear or failure. Recently, Rolls-Royce completed over 2000 hr of engine testing with the coated fan exit bypass vanes. There was no loss of coating after nearly 5000 typical engine cycles. Midway through the engine tests, the coated vanes were removed from the engine during a scheduled maintenance and inspection period. The vanes were shipped back to Glenn, where they underwent further stress testing in the Structural Dynamics Lab, mimicking more extreme conditions than those typical of the AE3007 engine cycle. These vanes were then replaced in the AE3007 and subjected to another 1000 hr of engine tests. Once again, there was no loss of coating and only a minimal appearance of cracking.

Description: An experimental study of three variations of a ventral nozzle system for supersonic short-takeoff and vertical-landing (SSTOVL) aircraft was performed at the NASA LeRC Powered Lift Facility. These test results include the effects of an annular duct flow into the ventral duct, a blocked tailpipe, and a short ventral duct length. An analytical study was also performed on the short ventral duct configuration using the PARC3D computational dynamics code. Data presented include pressure losses, thrust and flow performance, internal flow visualization, and pressure distributions at the exit plane of the ventral nozzle.

Description: Full temperature ejector model simulations are expensive, and difficult to implement experimentally. If an approximate similarity principle could be established, properly chosen performance parameters should be similar for both hot and cold flow tests if the initial Mach number and total pressures of the flow field are held constant. Existing ejector data is used to explore the utility of one particular similarity principle; the Munk and Prim similarity principle for isentropic flows. Static performance test data for a full-scale thrust augmenting ejector are analyzed for primary flow temperatures up to 1560 R. At different primary temperatures, exit pressure contours are compared for similarity. A nondimensional flow paramenter is then used to eliminate primary nozzle temperature dependence and verify similarity between the hot and cold flow experiments.

Description: An experimental study of three variations of a ventral nozzle system for supersonic short-takeoff and vertical-landing (SSTOVL) aircraft was performed at the NASA LeRC Powered Lift Facility. These test results include the effects of an annular duct flow into the ventral duct, a blocked tailpipe, and a short ventral duct length. An analytical study was also performed on the short ventral duct configuration using the PARC3D computational dynamics code. Data presented include pressure losses, thrust and flow performance, internal flow visualization, and pressure distributions at the exit plane of the ventral nozzle.

Description: The high-cycle fatigue of composite stator vanes provided an accelerated life-state prior to insertion in a test stand engine. The accelerated testing was performed in the Structural Dynamics Laboratory at the NASA Glenn Research Center under the guidance of Structural Mechanics and Dynamics Branch personnel. Previous research on fixturing and test procedures developed at Glenn determined that engine vibratory conditions could be simulated for polymer matrix composite vanes by using the excitation of a combined slip table and electrodynamic shaker in Glenn's Structural Dynamics Laboratory. Bench-top testing gave researchers the confidence to test the coated vanes in a full-scale engine test.

Description: The mechanical integrity of hard, erosion-resistant coatings were tested using the Structural Dynamics Laboratory at the NASA Glenn Research Center. Under the guidance of Structural Mechanics and Dynamics Branch personnel, fixturing and test procedures were developed at Glenn to simulate engine vibratory conditions on coated polymer-matrix- composite bypass vanes using a slip table in the Structural Dynamics Laboratory. Results from the high-frequency mechanical bench testing, along with concurrent erosion testing of coupons and vanes, provided sufficient confidence to engine-endurance test similarly coated vane segments. The knowledge gained from this program will be applied to the development of oxidation- and erosion-resistant coatings for polymer matrix composite blades and vanes in future advanced turbine engines. Fan bypass vanes from the AE3007 (Rolls Royce America, Indianapolis, IN) gas turbine engine were coated by Engelhard (Windsor, CT) with compliant bond coatings and hard ceramic coatings. The coatings were developed collaboratively by Glenn and Allison Advanced Development Corporation (AADC)/Rolls Royce America through research sponsored by the High-Temperature Engine Materials Technology Project (HITEMP) and the Higher Operating Temperature Propulsion Components (HOTPC) project. High-cycle fatigue was performed through high-frequency vibratory testing on a shaker table. Vane resonant frequency modes were surveyed from 50 to 3000 Hz at input loads from 1g to 55g on both uncoated production vanes and vanes with the erosion-resistant coating. Vanes were instrumented with both lightweight accelerometers and strain gauges to establish resonance, mode shape, and strain amplitudes. Two high-frequency dwell conditions were chosen to excite two strain levels: one approaching the vane's maximum allowable design strain and another near the expected maximum strain during engine operation. Six specimens were tested per dwell condition. Pretest and posttest inspections were performed optically at up to 60 magnification and using a fluorescent-dye penetrant. Accumulation of 10 million cycles at a strain amplitude of two to three times that expected in the engine (approximately 670 Hz and 20g) led to the development of multiple cracks in the coating that were only detectable using fluorescent-dye penetrant inspection. Cracks were prevalent on the trailing edge and on the convex side of the midsection. No cracking or spalling was evident using standard optical inspection at up to 60 magnification. Further inspection may reveal whether these fine cracks penetrated the coating or were strictly on the surface. The dwell condition that simulated actual engine conditions produced no obvious surface flaws even after up to 80 million cycles had been accumulated at strain amplitudes produced at approximately 1500 Hz and 45g.

Description: The Aero-Acoustic Propulsion Laboratory is an acoustically treated, 65-ft-tall dome located at the NASA Lewis Research Center. Inside this laboratory is the Nozzle Acoustic Test Rig (NATR), which is used in support of Advanced Subsonics Technology (AST) and High Speed Research (HSR) to test engine exhaust nozzles for thrust and acoustic performance under simulated takeoff conditions. Acoustic measurements had been gathered by a far-field array of microphones located along the dome wall and 10-ft above the floor. Recently, it became desirable to collect acoustic data for engine certifications (as specified by the Federal Aviation Administration (FAA)) that would simulate the noise of an aircraft taking off as heard from an offset ground location. Since nozzles for the High-Speed Civil Transport have straight sides that cause their noise signature to vary radially, an additional plane of acoustic measurement was required. Desired was an arched array of 24 microphones, equally spaced from the nozzle and each other, in a 25 off-vertical plane. The various research requirements made this a challenging task. The microphones needed to be aimed at the nozzle accurately and held firmly in place during testing, but it was also essential that they be easily and routinely lowered to the floor for calibration and servicing. Once serviced, the microphones would have to be returned to their previous location near the ceiling. In addition, there could be no structure could between the microphones and the nozzle, and any structure near the microphones would have to be designed to minimize noise reflections. After many concepts were considered, a single arched truss structure was selected that would be permanently affixed to the dome ceiling and to one end of the dome floor.

Description: The present invention provides for measurements of the principal strain magnitudes and directions, and maximum shear strain that occurs in a porous specimen, such as plastic, ceramic or porous metal, when it is loaded (or subjected to a load). In one embodiment the invention includes a capacitive delta extensometer arranged with six sensors in a three piece configuration, with each sensor of each pair spaced apart from each other by a predetermined angle, such as 120 degrees.

Description: The Exploration Laboratory Analysis (ELA) project supports the Exploration Medical Capability (ExMC) risk, which is stated as the Risk of Inability to Adequately Treat an Ill or Injured Crew Member, and ExMC Gap 4.05: Lack of minimally invasive in-flight laboratory capabilities with limited consumables required for diagnosing identified Exploration Medical Conditions. To mitigate this risk, the availability of inflight laboratory analysis instrumentation has been identified as an essential capability in future exploration missions. Mission architecture poses constraints on equipment and procedures that will be available to treat evidence-based medical conditions according to the Space Medicine Exploration Medical Conditions List (SMEMCL), and to perform human research studies on the International Space Station (ISS) that are supported by the Human Health and Countermeasures (HHC) element. Since there are significant similarities in the research and medical operational requirements, ELA hardware development has emerged as a joint effort between ExMC and HHC. In 2012, four significant accomplishments were achieved towards the development of exploration laboratory analysis for medical diagnostics. These achievements included (i) the development of high priority analytes for research and medical operations, (ii) the development of Level 1 functional requirements and concept of operations documentation, (iii) the selection and head-to-head competition of in-flight laboratory analysis instrumentation, and (iv) the phase one completion of the Small Business Innovation Research (SBIR) projects under the topic Smart Phone Driven Blood-Based Diagnostics. To utilize resources efficiently, the associated documentation and advanced technologies were integrated into a single ELA plan that encompasses ExMC and HHC development efforts. The requirements and high priority analytes was used in the selection of the four in-flight laboratory analysis performers. Based upon the competition results, a down select process will be performed in the upcoming year. Looking ahead, this unified effort has positioned each element for an in-flight lab analysis demonstration of select diagnostics measurements in the 2015 timeframe.