ALBERT

Description: System studies have shown the benefits of reducing blade tip clearances in modern turbine engines. Minimizing blade tip clearances throughout the engine will contribute materially to meeting NASA s Ultra-Efficient Engine Technology (UEET) turbine engine project goals. NASA GRC is examining two candidate approaches including rub-avoidance and regeneration which are explained in subsequent slides.

Description: Fretting is a structural damage mechanism observed when two nominally clamped surfaces are subjected to an oscillatory loading. A critical location for fretting induced damage has been identified at the blade/disk and blade/damper interfaces of gas turbine engine turbomachinery and space propulsion components. The high-temperature, high-frequency loading environment seen by these components lead to severe stress gradients at the edge-of-contact. These contact stresses drive crack nucleation and propagation in fretting and are very sensitive to the geometry of the contacting bodies, the contact loads, materials, temperature, and contact surface tribology (friction). To diagnose the threat that small and relatively undetectable fretting cracks pose to damage tolerance and structural integrity of in-service components, the objective of this work is to develop a well-characterized experimental fretting rig capable of investigating fretting behavior of advanced aerospace alloys subjected to load and temperature conditions representative of such turbomachinery components.

Description: This viewgraph presentation describes a turbine seal rig concept to meet next generation engine speed and temperatures requirements. The contents include: 1) Turbomachinery Seal Development Objectives; 2) High Temperature Turbomachinery Seal Test Rig; 3) Test Parameters; 4) Highlights of Engineering Calculations; 5) Seal Rig Global Thermal Analysis; 6) Test Rig Status; 7) Seal Rig Schematic; 8) Test Chamber Enlarged View; and 9) Rig Features Unique Measurement Systems.

Description: A commercially available code is utilized to analyze a plain and grooved liquid annular seal. These type seals are commonly used in modern turbopumps and have a pronounced effect on the rotordynamic behavior of these systems. Accurate prediction of both leakage and dynamic reaction forces is vital to ensure good performance and sound mechanical operation. The code SCISEAL developed by CFDRC is a generic 3-D, finite volume based CFD code solving the 3-D Reynolds averaged Navier Stokes equations. The code allows body-fitted, multi-blocked structured grids, turbulence modeling, rotating coordinate frames, as well as integration of dynamic pressure and shear forces on the rotating journal. The code may be used with the commercially available pre-and post-processing codes from CFDRC as well.

Description: The two dimensinal bifurcated inlet, down selected for the HSR program, and the engine bay cowling consist of many sealing interfaces. The variable geometry characteristics of this inlet and the size of the propulsion system impose new sealing requirements for commercial transport aircraft. Major inlet systems requiring seal development and testing include the ramp system, the bypass/take-off system, and the inlet/engine interface. Engine bay cowling seal interfaces include the inlet/cowling interface, the keel split line, the hinge beam/engine bay cowling, and the nozzle/cowling interface. These seals have to withstand supersonic flight operating temperatures and pressures with typical commercial aircraft reliability and lives. The operating conditions and expected seal lives will be identified for the various interfaces. Boeing's SST seal development program will also be discussed.

Description: The High Speed Civil Transport (HSCT) engine concept is a large mixed flow turbofan similar in construction to current military fighter engines. The mission, however, is quite different. The engine will operate for long periods of time at very high Mach numbers and high altitudes. The engine is required to have very low emissions and noise levels to be acceptable in commercial service. Current thrust levels are in the 55000 lb range. At the current supercruise speed requirement of Mach 2.4, the engine inlet temperature will be at least 380 F. This is the lowest cycle temperature expected anywhere in the propulsion system.Seals will be exposed to operate at this temperature and higher for thousands of hours without failure. Durability, cost, and weight will all be very important in determining the type of seals selected for a successful HSCT engine.

Description: New engines experience durability problems after entering service. The most prevalent and costly is the hot section, particularly the high-pressure turbine. The origin of durability problems can be traced back to: 1) the basic aero-mechanical design systems, assumptions, and design margins used by the engine designers, 2) the available materials systems, and 3) to a large extent, aggressive marketing in a highly competitive environment that pushes engine components beyond the demonstrated capability of the basic technology available for the hardware designs. Unfortunately the user must operate the engine in the service environment in order to learn the actual thrust loading and the time at max effort take-off conditions used in service are needed to determine the hot section life. Several hundred thousand hours of operational service will be required before the demonstrated reliability of a fleet of engines or the design deficiencies of the engine hot section parts can be determined. Also, it may take three to four engine shop visits for heavy maintenance on the gas path hardware to establish cost effective build standards. Spare parts drive the oerator's engine maintenance costs but spare parts also makes lots of money for the engine manufacturer during the service life of an engine. Unless competition prevails for follow-on engine buys, there is really no motivation for an OEM to spend internal money to improve parts durability and reduce earnings derived from a lucrative spare parts business. If the hot section life is below design goals or promised values, the OEM migh argue that the engine is being operated beyond its basic design intent. On the other hand, the airframer and the operator will continue to remind the OEM that his engine was selected based on a lot of promises to deliver spec thrust with little impact on engine service life if higher thrust is used intermittently. In the end, a standoff prevails and nothing gets fixed. This briefing will propose ways to hold competing engine manufacturers more accountable for engine hot section design margins during the entire Engine Development process as well as provide tools to assess the design temperature margins in the hot section parts of Service Engines.

Description: AlliedSignal aerospace company is committed to significantly improving the reliabilities of air/oil seals in their gas turbine engines. One motivation for this is that aircraft cabin air quality can be affected by the performance of mainshaft air/oil seals. In the recent past, coking related failure modes have been the focus of air/oil seal R&D at AlliedSignal. Many significant advances have been made to combat coke related failures, with some more work continuing in this area. This years R&D begins to address other commin failure modes. Among them, carbon seal "blistering" has been a chronic problem facing the sealing industry for many decades. AlliedSignal has launched an aggressive effort this year to solve this problem for our aerospace rated carbon seals in a short (one to two year) timeframe. Work also continues in developing more user-friendly tools and data for seal analysis & design. Innovations in seal cooling continue. Nominally non-contacting hydropad sealing concept is being developed for aerospace applications. Finally, proprietary work is in planning stages for development of a seal with the aggressive aim of zero oil leakage.

Description: The author will present results obtained to date of a secondary flow study currently being conducted. The purpose of the study is to investigate and report all the ramifications of introducing advanced sealing technology into gas turbine engine secondary flow systems. In addition to detailed cost/benefit results we will also derive seal operational requirements which can be fed into a subsequent advanced seal development program. Using the current Allison AE3007 engine as a model/baseline we have examined 6 different advanced seal variations. We have settled on a design with 2 advanced seals which results n a savings of 2% in chargeable cooling. The introduction of these advanced seals has resulted in substantial changes to surrounding engine components which will be reported.

Description: This paper presents an overview of the design methodology used in the development of the aerodynamic configuration of the nacelle core compartment vent for a typical Boeing commercial airplane together with design challenges for future design efforts. Core compartment vents exhaust engine subsystem flows from the space contained between the engine case and the nacelle of an airplane propulsion system. These subsystem flows typically consist of precooler, oil cooler, turbine case cooling, compartment cooling and nacelle leakage air. The design of core compartment vents is challenging due to stringent design requirements, mass flow sensitivity of the system to small changes in vent exit pressure ratio, and the need to maximize overall exhaust system performance at cruise conditions.

Description: Airlines are extremely sensitive to the amount of dollars spent on maintaining the external engine hardware in the field. Analysis reveals that many problems revolve around a central issue, reliability. Fuel and oil leakage due to seal failure and electrical fault messages due to wire harness failures play a major role in aircraft delays and cancellations (D&C's) and scheduled maintenance. Correcting these items on the line requires a large investment of engineering resources and manpower after the fact. The smartest and most cost effective philosophy is to build the best hardware the first time. The only way to do that is to completely understand and model the operating environment, study the field experience of similar designs and to perform extensive testing.

Description: The proven technology of brush seals has been extended to the mitigation of problems arising from friction and wear at the bristle-rotor interface at high surface speeds. In prototype testing, the brush is mounted on, and free to rotate with the shaft, thus providing a complaint primary seal. A face seal positioned between the backing plate of the brush seal and the housing provides a secondary seal. The purpose of this paper is to demonstrate the interaction between the brush bristles and the shaft at high surface speeds as well as introduce a numerical model to simulate the bristle behavior. A test facility was constructed to study the effects of centrifugal forces on bristle deflection in a single rotating brush seal. The bristle-rotor interface was observed through a video camera, which utilized a high magnification borescope and a high frequency strobe light source. Rotational speeds of the rotor and the brush seal were measured by a magnetic and optical speed sensor, respectively. Preliminary results with speeds up to 11,000 rpm show no speed differential between the brush seal and rotor, or any instability problems associated with the brush seal. Bristle liftoff from the rotor is successfully captured on video.

Description: The U-Plex(Registered TradeMark) was designed to allow greater elastic deflection capability in a given gland volume than the now conventional E-seal(Regitered TradeMark). Greater deflection capability with the associated lower bending stresses provides several benefits. For pneumatic duct joints, the axial free height is increased to allow sealing of flanges with weld distortions significantly in excess of what could be tolerated with E-seals(Registered TradeMark), This performance is achieved while maintaining the reusability and ease of assembly typical of E-seal(Registered TradeMark) rigid duct joints.

Description: The nature of the RS-68 turbopumps requires that the hydrogen seals separating the pump from the turbine must have extremely low levels of leakage and be contained in small packages. Conventional seal technologies are not able to reasonably satisfy such design requirements. A review of experimental measurements and analysis publications suggests that brush seals are well suited for the design requirements. Brush seals are shown to have less leakage than conventional labyrinth and damper seals and have no adverse effects on the rotordynamics of the machine. The bulk-flow analysis presented by Hendricks et al. is used as a guideline to create a spreadsheet that provides mass flow through the seal and heat generated by the rubbing contact of the bristles on the shaft. The analysis is anchored to published data for LN2 and LH2 leakage tests. Finally, the analysis is used to design seals for both applications. It is observed that the most important analysis parameter is the thickness of the bristle pack and its relationship to seal clearance, lay angle and pressure drop.

Description: The configuration of the propulsion system engine externals must meet many airplane requirements such as cost, thrust, weight, range and systems power extraction. On the 737-700 several program requirements also played a major role in the development of the engine externals. These program goals were increased range, same cost as a 1994 737-300, 15% reduction in maintenance costs from the 737-300, and a propulsion package that appeared as if it was designed by one company. This presentation will show how these requirements shaped the design of the engine externals for the 737-700/CFM56-7B.

Description: Two numerical approaches are used to model the interaction between the turbine main gas flow and the wheelspace cavity seal flow. The 3-D, unsteady Reynolds-averaged Navier-Stokes equations are solved with a CFD code based on a structured grid to study the interaction between the turbine main gas flow and the wheelspace cavity seal flow. A CFD code based on an unstructured grid is used to solve detailed flow feature in the cavity seal which has a complex geometry. The numerical results confirm various observations from earlier experimental studies under similar flow conditions. When the flow rate through the rim cavity seal is increased, the ingestion of the main turbine flow into the rim seal area decreases drastically. However, a small amount of main gas flow is ingested to the rim seal area even with very high level of seal flow rate. This is due to the complex nature of 3-D, unsteady flow interaction near the hub of the turbine stage.

Description: The overview for HSR seals includes defining objectives, summarizing sealing and material requirements, presenting relevant seal cross-sections, and identifying technology needs. Overview presentations are given for the inlet, turbomachinery, combustor and nozzle. The HSCT and HSR seal issues center on durability and efficiency of rotating equipment seals, structural seals and high speed bearing and sump seals. Tighter clearances, propulsion system size and thermal requirements challenge component designers.

Description: During an aerospace engineer's undergraduate studies, he or she will attend classes in aerodynamics, thermodynamics, structures, stability and control, dynamics, design, propulsion, and computer science, along with the related courses in mathematics, physics, statistics, and chemistry required to understand the material. Upon graduation, the new engineer will have acquired a basic knowledge of how to build an aerospace vehicle. What only comes through experience, however, is the understanding of the inevitable imperfect process through which an aerospace vehicle is built. This is the adventure of turning a basic concept into functional hardware. Engineers working on a project must often deal with ambiguous situations. They are routinely asked by management to provide risk assessments of a project, yet even after careful analysis uncertainties remain. The project must be accomplished within finite limits of time and money. The question an engineer answers is whether the solution to potential problem is worth the cost and schedule delay, or if the solution might actually be worse than the problem it is meant to solve. Review protocols are established to ensure that an unknown has not been overlooked. But these cannot protect against an unknown unknown. Examples of these situations can be found in the history of the X-43A Hyper-X (Hypersonic Experiment) program. In this NASA project, a supersonic combustion ramjet (scramjet) engine was flight tested on a subscale vehicle. The X-43A Hyper-X Research Vehicle (HXRV) was launched from a B-52B mothership, then boosted to the test speed by a modified Pegasus rocket first stage, called the Hyper-X Launch Vehicle (HXLV). Once at the proper speed and altitude, the X-43A separated from the booster, stabilized itself, and then the engine test began. Although wind-tunnel scramjet engine tests had begun in the late 1950s, before the Hyper-X program there had never been an actual in-flight test of such an engine integrated with an appropriate airframe. Thus, while the scramjet had successfully operated in the artificial airflow of wind tunnels, the concept had yet to be proven in real air. These conditions meant changes in density and temperature, as well as changes in angle of attack and sideslip of a free-flying vehicle. A wind tunnel is limited in its ability to simulate these subtle factures, which have a major impact on almost any vehicle, but especially that of a scramjet's performance. The Hyper-X project was to provide a real-world benchmark of the ground test data. The full scale X-43A engine would be operated in the wind tunnel, and then flown, and the data from its operation would then be compared with projections. If these matched, the wind tunnel data would be considered a reliable design tool for future scramjet. If there were significant differences, the reasons for these would have to be identified. Until such information was available, scramjets would lack the technological maturity to be considered for future space launch or high-speed atmospheric flight vehicles.

Description: The objective is to develop and demonstrate a fast-acting active clearance control system to improve turbine engine performance, reduce emissions, and increase service life. System studies have shown the benefits of reducing blade tip clearances in modern turbine engines. Minimizing blade tip clearances throughout the engine will contribute materially to meeting NASA's Ultra-Efficient Engine Technology (UEET) turbine engine project goals. NASA GRC is examining two candidate approaches including rub-avoidance and regeneration which are explained in subsequent slides.

Description: To achieve jet noise reduction goals for the High Speed Civil Transport aircraft, researchers have been investigating the mixer-ejector nozzle concept. For this concept, a primary nozzle with multiple chutes is surrounded by an ejector. The ejector mixes low-momentum ambient air with the hot engine exhaust to reduce the jet velocity and, hence, the jet noise. It is desirable to mix the two streams as fast as possible in order to minimize the length and weight of the ejector. An earlier model of the mixer-ejector nozzle was tested extensively in the Aerodynamic Research Laboratory (ARL) of GE Aircraft Engines at Cincinnati, Ohio. While testing was continuing with later generations of the nozzle, the earlier model was brought to the NASA Lewis Research Center for relatively fundamental measurements. Goals of the Lewis study were to obtain details of the flow field to aid computational fluid dynamics (CFD) efforts and obtain a better understanding of the flow mechanisms, as well as to experiment with mixing enhancement devices, such as tabs. The measurements were made in an open jet facility for cold (unheated) flow without a surrounding coflowing stream.

Description: In a continuing research program, jets from nozzles of different geometries are being investigated with the aim of increasing mixing and spreading in those flows. Flow fields from nozzles with elliptic, rectangular, and other more complex cross-sectional shapes are being studied in comparison to circular nozzles over a wide Mach number range. As noted by previous researchers, noncircular jets usually spread faster than circular jets. Another technique being investigated to increase jet spreading even further for a given nozzle is the use of "tabs" to generate vortices. A typical tab is a triangular-shaped protrusion placed at the nozzle exit, with the base of the triangle touching the nozzle wall and the apex leaning downstream at 45 to the stream direction. This geometry was determined by a parametric study to produce the optimum effect for a given area blockage. The tabs can increase jet spreading significantly. The underlying mechanism traces to a pair of counter-rotating streamwise vortices originating from each tab. These vortex pairs persist in the flow; and with the appropriate number and strength, they can increase spreading.

Description: Because of its high efficiency, fuel cell technology may be used to launch a new generation of more-electric aeropropulsion and power systems for future aircraft. Electric-motor-driven airplanes using fuel-cell powerplants would be beneficial to the environment because of fuel savings, low noise, and zero carbon-dioxide emissions. In spite of the fuel cell s efficiency benefit, to produce the same shaft drive power, a fuel cell- powered electric-drive system must be definitely heavier than a turbine-drive system. However, the fuel-cell system s overall efficiency from fuel-to-shaft power is higher than for a turbine-drive system. This means that the fuel consumption rate could be lower than for a conventional system. For heavier, fuel-laden planes for longer flights, we might achieve substantial fuel savings. In the airplane industry, in fact, an efficiency gain of even a few percentage points can make a major economic difference in operating costs.

Description: With growing concerns about global warming, there is a need to develop pollution-free aircraft. One approach is to use hydrogen-fueled aircraft that use fuel cells or turbogenerators to produce electric power to drive the electric motors that turn the aircraft s propulsive fans. Hydrogen fuel would be carried as a liquid, stored at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are too heavy for aircraft propulsion. We need to develop high-power, lightweight electric motors (highpower- density motors). One approach is to increase the conductivity of the wires by cooling them with liquid hydrogen (LH2). This would allow superconducting rotors with an ironless core. In addition, the motor could use very pure aluminum or copper, substances that have low resistances at cryogenic temperatures. A preliminary design of a 450-hp LH2-cooled electric motor was completed and is being manufactured by a contractor. This motor will be tested at the NASA Glenn Research Center and will be used to test different superconducting materials such as magnesium diboride (MgB2). The motor will be able to operate at speeds of up to 6000 rpm.

Description: The theory of discrete event supervisory (DES) control was applied to the optimal control of a twin-engine aircraft propulsion system and demonstrated in a simulation. The supervisory control, which is implemented as a finite-state automaton, oversees the behavior of a system and manages it in such a way that it maximizes a performance criterion, similar to a traditional optimal control problem. DES controllers can be nested such that a high-level controller supervises multiple lower level controllers. This structure can be expanded to control huge, complex systems, providing optimal performance and increasing autonomy with each additional level. The DES control strategy for propulsion systems was validated using a distributed testbed consisting of multiple computers--each representing a module of the overall propulsion system--to simulate real-time hardware-in-the-loop testing. In the first experiment, DES control was applied to the operation of a nonlinear simulation of a turbofan engine (running in closed loop using its own feedback controller) to minimize engine structural damage caused by a combination of thermal and structural loads. This enables increased on-wing time for the engine through better management of the engine-component life usage. Thus, the engine-level DES acts as a life-extending controller through its interaction with and manipulation of the engine s operation.

Description: Current aircraft engine controllers are designed and operated to provide desired performance and stability margins. Except for the hard limits for extreme conditions, engine controllers do not usually take engine component life into consideration during the controller design and operation. The end result is that aircraft pilots regularly operate engines under unnecessarily harsh conditions to strive for optimum performance. The NASA Glenn Research Center and its industrial and academic partners have been working together toward an intelligent control concept that will include engine life as part of the controller design criteria. This research includes the study of the relationship between control action and engine component life as well as the design of an intelligent control algorithm to provide proper tradeoffs between performance and engine life. This approach is expected to maintain operating safety while minimizing overall operating costs. In this study, the thermomechanical fatigue (TMF) of a critical component was selected to demonstrate how an intelligent engine control algorithm can significantly extend engine life with only a very small sacrifice in performance. An intelligent engine control scheme based on modifying the high-pressure spool speed (NH) was proposed to reduce TMF damage from ground idle to takeoff. The NH acceleration schedule was optimized to minimize the TMF damage for a given rise-time constraint, which represents the performance requirement. The intelligent engine control scheme was used to simulate a commercial short-haul aircraft engine.

Description: The future of aviation propulsion systems is increasingly focused on the application of control technologies to significantly enhance the performance of a new generation of air vehicles. Active flow control refers to a set of technologies that manipulate the flow of air and combustion gases deep within the confines of an engine to dynamically alter its performance during flight. By employing active flow control, designers can create engines that are significantly lighter, are more fuel efficient, and produce lower emissions. In addition, the operating range of an engine can be extended, yielding safer transportation systems. The realization of these future propulsion systems requires the collaborative development of many base technologies to achieve intelligent, embedded control at the engine locations where it will be most effective. NASA Glenn Research Center s Controls and Dynamics Technology Branch has developed a state-of-the-art low-speed Active Flow Control Laboratory in which emerging technologies can be integrated and explored in a flexible, low-cost environment. The facility allows the most promising developments to be prescreened and optimized before being tested on higher fidelity platforms, thereby reducing the cost of experimentation and improving research effectiveness.

Description: The transformation of engine control systems from centralized to distributed architecture is both necessary and enabling for future aeropropulsion applications. The continued growth of adaptive control applications and the trend to smaller, light weight cores is a counter influence on the weight and volume of control system hardware. A distributed engine control system using high temperature electronics and open systems communications will reverse the growing trend of control system weight ratio to total engine weight and also be a major factor in decreasing overall cost of ownership for aeropropulsion systems. The implementation of distributed engine control is not without significant challenges. There are the needs for high temperature electronics, development of simple, robust communications, and power supply for the on-board electronics.

Description: Advanced model-based control architecture overcomes the limitations state-of-the-art engine control and provides the potential of virtual sensors, for example for thrust and stall margin. "Tracking filters" are used to adapt the control parameters to actual conditions and to individual engines. For health monitoring standalone monitoring units will be used for on-board analysis to determine the general engine health and detect and isolate sudden faults. Adaptive models open up the possibility of adapting the control logic to maintain desired performance in the presence of engine degradation or to accommodate any faults. Improved and new sensors are required to allow sensing at stations within the engine gas path that are currently not instrumented due in part to the harsh conditions including high operating temperatures and to allow additional monitoring of vibration, mass flows and energy properties, exhaust gas composition, and gas path debris. The environmental and performance requirements for these sensors are summarized.

Description: Active Control can help to meet future engine requirements by an active improvement of the component characteristics. The concept is based on an intelligent control logic, which senses actual operating conditions and reacts with adequate actuator action. This approach can directly improve engine characteristics as performance, operability, durability and emissions on the one hand. On the other hand active control addresses the design constrains imposed by unsteady phenomena like inlet distortion, compressor surge, combustion instability, flow separations, vibration and noise, which only occur during exceptional operating conditions. The feasibility and effectiveness of active control technologies have been demonstrated in lab-scale tests. This chapter describes a broad range of promising applications for each engine component. Significant efforts in research and development remain to implement these technologies in engine rig and finally production engines and to demonstrate today s engine generation airworthiness, safety, reliability, and durability requirements. Active control applications are in particular limited by the gap between available and advanced sensors and actuators, which allow an operation in the harsh environment in an aero engine. The operating and performance requirements for actuators and sensors are outlined for each of the gas turbine sections from inlet to nozzle.

Description: New challenges concerning system health-monitoring and life-extending robust controls for the Ultra-Efficient Engine Technology Project, as well as other advanced engine and power system concepts at NASA and elsewhere, have renewed the control community s interest in smart, model-based methods. In particular, these challenges have further motivated efforts at the NASA Glenn Research Center to exploit the versatility and superiority of the dynamic features extraction of multiscale analysis for controls--such as with "wavelets" and "wavelet filter-banks.' The accomplishments reported herein pertain to the active suppression of combustion instabilities in liquid-fuel combustors via fuel modulation. The fundamentals and initial success of this innovation were reported for a unique demonstration of active combustion control (a research collaboration of NASA Glenn with Pratt & Whitney and the United Technologies Research Center, UTRC). This demonstration, conducted in 2002 at UTRC on the NASA single nozzle rig (SNR) combustor, was the first known suppression of high-frequency instability with a liquid-fueled combustor. The SNR is based on a high-powered military engine combustor that exhibited well-known instabilities.

Description: The operational envelope of gas turbine engines is constrained by the stability limit of the compression system. The dangers of exceeding this limit are severe, with the potential for engine failure and loss of the aircraft. To avoid such failures, compressor designers provide an adequate stability (stall) margin in the compressor design to account for inlet distortions, degradation due to wear, throttle transients, and other factors that reduce compressor stability from the original design intent. In some cases, the required stall margin results in the compressor operating line being below the maximum efficiency potential of the compression system. Current approaches to increasing stability tend to decrease the efficiency of the compressor. The focus of this work is to increase the stall margin of compressors without decreasing their efficiency.

Description: Future advanced aircraft fueled by hydrogen are being developed to use electric drive systems instead of gas turbine engines for propulsion. Current conventional electric motor power densities cannot match those of today s gas turbine aircraft engines. However, if significant technological advances could be made in high-power-density motor development, the benefits of an electric propulsion system, such as the reduction of harmful emissions, could be realized.

Description: A comparison of the operating characteristics of 75-millimeter-bore (size 215) cylindrical-roller one-piece inner-race-riding cage-type bearings was made using a laboratory test rig and a turbojet engine. Cooling correlation parameters were determined by means of dimensional analysis, and the generalized results for both the inner- and outer-race bearing operating temperatures are compared for the laboratory test rig and the turbojet engine. Inner- and outer-race cooling-correlation curves were obtained for the turbojet-engine turbine-roller bearing with the same inner- and outer-race correlation parameters and exponents as those determined for the laboratory test-rig bearing. The inner- and outer-race turbine roller-bearing temperatures may be predicted from a single curve, regardless of variations in speed, load, oil flow, oil inlet temperature, oil inlet viscosity, oil-jet diameter or any combination of these parameters. The turbojet-engine turbine-roller-bearing inner-race temperatures were 30 to 60 F greater than the outer-race-maximum temperatures, the exact values depending on the operating condition and oil viscosity; these results are in contrast to the laboratory test-rig results where the inner-race temperatures were less than the outer-race-maximum temperatures. The turbojet-engine turbine-roller bearing, maximum outer-race circumferential temperature variation was approximately 30 F for each of the oils used. The effect of oil viscosity on inner- and outer-race turbojet-engine turbine-roller-bearing temperatures was found to be significant. With the lower viscosity oil (6x10(exp -7) reyns (4.9 centistokes) at 100 F; viscosity index, 83), the inner-race temperature was approximately 30 to 35 F less than with the higher viscosity oil (53x10(exp -7) reyns (42.8 centistokes) at 100 F; viscosity index, 150); whereas the outer-race-maximum temperatures were 12 to 28 F lower with the lower viscosity oil over the DN range investigated.

Description: A literature survey was conducted to determine the relation between aircraft ignition sources and inflammables. Available literature applicable to the problem of aircraft fire hazards is analyzed and, discussed herein. Data pertaining to the effect of many variables on ignition temperatures, minimum ignition pressures, and minimum spark-ignition energies of inflammables, quenching distances of electrode configurations, and size of openings incapable of flame propagation are presented and discussed. The ignition temperatures and the limits of inflammability of gasoline in air in different test environments, and the minimum ignition pressure and the minimum size of openings for flame propagation of gasoline - air mixtures are included. Inerting of gasoline - air mixtures is discussed.

Description: Tests of two propellers having two blades and differing only in the inboard pitch distribution were made in the Langley 8-foot highspeed tunnel to determine the effect of inboard pitch distribution on propeller performance. propeller was designed for operation in the reduced velocity region ahead of an NACA cowling; the inboard pitch distribution of the modified propeller was increased for operation at or near free-stream velocities, such as would be obtained in a pusher installation. conditions covering climb, cruise, and high-speed operation. Wake surveys were taken behind the propellers in order to determine the distribution of thrust along the blades and to aid in the analysis of the results. Test results showed that the modified propeller was about 2.5 percent less efficient for a typical climb condition at all altitudes, 2 percent more efficient for one cruise condition, and 5 percent more efficient for high-speed operation. speed condition, the modified propeller showed a 6-percent loss in efficiency due to compressibility; whereas the original propeller showed an 11-percent efficiency loss due to compressiblity. The lower compressibility loss for the modified propeller resulted from the fact that the inboard sections of this propeller could operate at increased thrust loading after compressibility losses had occurred at the outboard sections.

Description: Turbine vane heat transfer predictions are given for smooth and rough vanes where the experimental data show transition moving forward on the vane as the surface roughness physical height increases. Consistent with smooth vane heat transfer, the transition moves forward for a fixed roughness height as the Reynolds number increases. Comparisons are presented with published experimental data. Some of the data are for a regular roughness geometry with a range of roughness heights, Reynolds numbers, and inlet turbulence intensities. The approach taken in this analysis is to treat the roughness in a statistical sense, consistent with what would be obtained from blades measured after exposure to actual engine environments. An approach is given to determine the equivalent sand grain roughness from the statistics of the regular geometry. This approach is guided by the experimental data. A roughness transition criterion is developed, and comparisons are made with experimental data over the entire range of experimental test conditions. Additional comparisons are made with experimental heat transfer data, where the roughness geometries are both regular and statistical. Using the developed analysis, heat transfer calculations are presented for the second stage vane of a high pressure turbine at hypothetical engine conditions.

Description: Computational fluid dynamics (CFD) was used to evaluate the flow field and thrust performance of a promising concept for reducing the noise at take-off of dual-stream turbofan nozzles. The concept, offset stream technology, reduces the jet noise observed on the ground by diverting (offsetting) a portion of the fan flow below the core flow, thickening and lengthening this layer between the high-velocity core flow and the ground observers. In this study a wedge placed in the internal fan stream is used as the diverter. Wind, a Reynolds averaged Navier-Stokes (RANS) code, was used to analyze the flow field of the exhaust plume and to calculate nozzle performance. Results showed that the wedge diverts all of the fan flow to the lower side of the nozzle, and the turbulent kinetic energy on the observer side of the nozzle is reduced. This reduction in turbulent kinetic energy should correspond to a reduction in noise. However, because all of the fan flow is diverted, the upper portion of the core flow is exposed to the freestream, and the turbulent kinetic energy on the upper side of the nozzle is increased, creating an unintended noise source. The blockage due to the wedge reduces the fan mass flow proportional to its blockage, and the overall thrust is consequently reduced. The CFD predictions are in very good agreement with experimental flow field data, demonstrating that RANS CFD can accurately predict the velocity and turbulent kinetic energy fields. While this initial design of a large scale wedge nozzle did not meet noise reduction or thrust goals, this study identified areas for improvement and demonstrated that RANS CFD can be used to improve the concept.

Description: As the aviation industry moves toward higher efficiency electrical power generation, all electric aircraft, or zero emissions and more quiet aircraft, fuel cells are sought as the technology that can deliver on these high expectations. The hybrid solid oxide fuel cell system combines the fuel cell with a micro-turbine to obtain up to 70% cycle efficiency, and then distributes the electrical power to the loads via a power distribution system. The challenge is to understand the dynamics of this complex multidiscipline system and the design distributed controls that take the system through its operating conditions in a stable and safe manner while maintaining the system performance. This particular system is a power generation and a distribution system, and the fuel cell and micro-turbine model fidelity should be compatible with the dynamics of the power distribution system in order to allow proper stability and distributed controls design. The novelty in this paper is that, first, the case is made why a high fidelity fuel cell mode is needed for systems control and stability designs. Second, a novel modeling approach is proposed for the fuel cell that will allow the fuel cell and the power system to be integrated and designed for stability, distributed controls, and other interface specifications. This investigation shows that for the fuel cell, the voltage characteristic should be modeled but in addition, conservation equation dynamics, ion diffusion, charge transfer kinetics, and the electron flow inherent impedance should also be included.

Description: An integrated team of NASA personnel, Government contractors, industry partners, and university staff have developed an innovative new technology for commercial fan cases that will substantially influence the safety and efficiency of future turbine engines. This effective team, under the direction of the NASA Glenn Research Center and with the support of the Federal Aviation Administration, has matured a new class of carbon/polymer composites and demonstrated a 30- to 50-percent improvement in specific containment capacity (blade fragment kinetic energy/containment system weight). As the heaviest engine component, the engine case/containment system greatly affects both the safety and efficiency of aircraft engines. The ballistic impact research team has developed unique test facilities and methods for screening numerous candidate material systems to replace the traditional heavy, metallic engine cases. This research has culminated in the selection of a polymer matrix composite reinforced with triaxially braided carbon fibers and technology demonstration through the fabrication of prototype engine cases for three major commercial engine manufacturing companies.

Description: Pollution-free flight is one of NASA s goals for the 21st century. One method of approaching that goal is to use hydrogen-fueled aircraft that use fuel cells or turbogenerators to produce electric power to drive electric motors that turn the aircraft s propulsive fans or propellers. Hydrogen fuel would likely be carried as a liquid, stored in tanks at hydrogen s boiling point of 20.5 K (-422.5 F). The liquid hydrogen could provide essentially free refrigeration to cool electric motor windings before being used as fuel. Either superconductivity or the low resistance of pure copper or aluminum in liquid hydrogen could be applied to greatly increase electric current density and motor power density.

Description: Ongoing research in NASA Glenn Research Center s Structural Mechanics and Dynamics Branch to develop smart materials technologies for adaptive aeropropulsion components has resulted in the design of a prototype variable-area exhaust nozzle (see the preceding photograph). The novel design exploits the potential of smart materials to improve the performance of existing fixed-area exhaust nozzles by introducing new capabilities for adaptive shape control, vibration damping, and flow manipulation. The design utilizes two different smart materials: shape memory alloy wires as actuators and magnetorheological fluids as damper locks.

Description: Large axial loads are induced on the rolling element bearings of a gas turbine. To extend bearing life, designers use pneumatic balance pistons to reduce the axial load on the bearings. A magnetic thrust bearing could replace the balance pistons to further reduce the axial load. To investigate this option, the U.S. Army Research Laboratory, the NASA Glenn Research Center, and Texas A&M University designed and fabricated a 7-in.- diameter magnetic thrust bearing to operate at 1000 F and 30,000 rpm, with a 1000-lb load capacity. This research was funded through a NASA Space Technology Transfer Act with Allison Advance Development Company under the Ultra-Efficient Engine Technology (UEET) Intelligent Propulsion Systems Foundation Technology project.

Description: With growing concerns about global warming, there is a need to develop pollution-free aircraft. One approach is to use hydrogen-fueled airc raft that use fuel cells or turbogenerators to produce electric power to drive the electric motors that turn the aircraft#s propulsive fan s. Hydrogen fuel would be carried as a liquid, stored at its boiling point of 20.5 K (-422.5 ?F). Conventional electric motors, however, are too heavy to use on an aircraft. We need to develop high-power, lig htweight electric motors (high-powerdensity motors).

Description: A subelement-level ultimate strength test was completed successfully at the NASA Glenn Research Center (http://www.nasa.gov/glenn/) on a large gamma titanium aluminide (TiAl) inlet flap demonstration piece. The test subjected the part to prototypical stress conditions by using unique fixtures that allowed both loading and support points to be located remote to the part itself (see the photograph). The resulting configuration produced shear, moment, and the consequent stress topology proportional to the design point. The test was conducted at room temperature, a harsh condition for the material because of reduced available ductility. Still, the peak experimental load-carrying capability exceeded original predictions.

Description: The NASA Glenn Research Center and academic partners are developing advanced multiagent robotic control algorithms that will enable the autonomous inspection and repair of future propulsion systems. In this application, on-wing engine inspections will be performed autonomously by large groups of cooperative miniature robots that will traverse the surfaces of engine components to search for damage. The eventual goal is to replace manual engine inspections that require expensive and time-consuming full engine teardowns and allow the early detection of problems that would otherwise result in catastrophic component failures. As a preliminary step toward the long-term realization of a practical working system, researchers are developing the technology to implement a proof-of-concept testbed demonstration. In a multiagent system, the individual agents are generally programmed with relatively simple controllers that define a limited set of behaviors. However, these behaviors are designed in such a way that, through the localized interaction among individual agents and between the agents and the environment, they result in self-organized, emergent group behavior that can solve a given complex problem, such as cooperative inspection. One advantage to the multiagent approach is that it allows for robustness and fault tolerance through redundancy in task handling. In addition, the relatively simple agent controllers demand minimal computational capability, which in turn allows for greater miniaturization of the robotic agents.

Description: Electric propulsion systems are quickly emerging as attractive options for primary propulsion in low Earth orbit, in geosynchronous orbit, and on interplanetary spacecraft. The driving force behind the acceptance of these systems is the substantial reduction in the propellant mass that can be realized. Unfortunately, system designers are often forced to utilize components designed for chemical propellants in their electric systems. Although functionally acceptable, these relatively large, heavy components are designed for the higher pressures and mass flow rates required by chemical systems. To fully realize the benefits of electric propulsion, researchers must develop components that are optimized for the low flow rates, critical leakage needs, low pressures, and limited budgets of these emerging systems.

Description: The gas turbine industry used a variety of sealing mechanisms to contain and direct secondary flows into and around components for cooling, and to limit leakage into and from bearing and disk cavities. The function of these seals is very important to the component efficiencies and attendant engine performance. Most of these seals are labyrinth seals, which are high-leakage seals that are costly to manufacture. In recent years, brush seals have been introduced which have demonstrated significantly reduced leakage, although they are still expensive and have exhibited wear and hysteresis difficulties. A new innovative concept called finger seal, patented by AlliedSignal, has demonstrated leakage similar to brush seals and is cheaper. The finger seal is comprised of a stack of precision photo-etched sheet metal elements, which allows intricate features to be made at very low cost and with the potential to resist wear and provide the compliance necessary to accomodate rotor excursions. Initial testing in the high-speed/high-temperature seal test facility, at the NASA Lewis Research Center, has corroborated the finger seal performance. The testing also revealed hysteresis problems with the current design. A NASA funded research project is in progress to correct the functional deficiencies of the finger seal and to refine its features to provide sufficient seal life for commercial transport engines and other long-life applications. This research will benefit the aeronautical gas turbine industry as a whole in terms of fuel consumption, operational characteristics, and cost. The first phase of this research to reduce finger seal hysteresis has been in progress for the last one year. This paper presents the results of this research to date. In future the research program will address seal performance, manufacturing, cost and life issues. The research program is expected to be completed by December 1998.

Description: A 36" diameter aspirating face seal for aircraft engine application has undergone extensive testing and analysis. Previous testing indicated that the seal tended to seek equilibrium at axial rotor clearances that were larger than expected. Parameter studies were conducted on several seal design parameters to evaluate effect on seal performance. Mixing of air flows from the air dam and air bearing regions of the seal was shown to have a significant impact on the seal's performance. Two methods of minimizing this flow interaction were studied both analytically and experimentally. The first method is to reduce the labyrinth tooth clearance, thereby limiting flow to the air dam itself. The second method involves utilizing a flow deflector between the air dam and air bearing regions of the seal in order to prevent radial flow from the air dam from disrupting the formation of a hydrostatic film at the air bearing. Both methods were shown to be effective design enhancements, allowing seal closure to be achieved. In both cases, the seal seeks an equilibrium position 0.0015" from the rotor surface, with corresponding low leakage rates.

Description: Experiments are being conducted to gain an understanding of the physics of rim scale cavity ingestion in a turbine stage with the high-work, single-stage characteristics envisioned for Advanced Subsonic Transport (AST) aircraft gas turbine engines fo the early 21st century. Initial experimental measurements to be presented include time-averaged turbine rim cavity and main gas path static pressure measurements for rim seal coolant to main gas path mass flow ratios between 0 and 0.02. The ultimate objective of this work is develop improved rim seal design concepts for use in modern high-work, single sage turbines n order to minimize the use of secondary coolant flow. Toward this objective the time averaged and unsteady data to be obtained in these experiments will be used to 1) Quantify the impact of the rim cavity cooling air on the ingestion process. 2) Quantify the film cooling benefits of the rim cavity purge flow in the main gas path. 3) Quantify the impact of the cooling air on turbine efficiency. 4) Develop/evaluate both 3D CFD and analytical models of the ingestion/cooling process.

Description: Engine external components include all the fluid carrying, electron carrying, and support devices that are needed to operate the propulsion system. These components are varied and include: pumps, valves, actuators, solenoids, sensors, switches, heat exchangers, electrical generators, electrical harnesses, tubes, ducts, clamps and brackets. The failure of any component to perform its intended function will result in a maintenance action, a dispatch delay, or an engine in flight shutdown. The life of each component, in addition to its basic functional design, is closely tied to its thermal and dynamic environment .Therefore, to reach a mature design life, the component's thermal and dynamic environment must be understood and controlled, which can only be accomplished by attention to design analysis and testing. The purpose of this paper is to review analysis and test techniques toward achieving good component health.

Description: Numerical computation predicts that an elastic support can substantially improve the stability of the wave bearing if the dynamic stiffness and damping of this support are in a specific range of values. To experimentally validate this prediction, the housing of a gas bearing was mounted on elastic O-rings and the threshold of sub-synchronous whirl motion was experimentally observed when the bearing runs unloaded with a rotating speed up to 30,000 RPM. The O-ring system was also dynamically characterized by measuring its stiffness and damping at various frequencies up to 500 Hz. Good correlation exists between the experimental data and numerical prediction.

Description: The combuster section of the High Speed Civil Transport (HSCT) requires high temperature seals to minimize leakage between CMC components. The temperature requirements range from 1500 F to 2100 F and the compression requirements range from 10% to 50%. Three distinctly different Nextel braided seals have been developed to seal areas such as the bulkhead heatshields and lean zone outer liner. The seals range from 0.10" dia. rope to triangular braid with 1" sides.

Description: The leading Aeronautics program within NASA is the High Speed Research Program (HSR). The HSR program's highest priorities are high pay-off technologies for airframe and propulsion systems required for a high speed civil transport (HSCT). These priorities have been developed collaboratively with NASA, FAA and the US Industry (Boeing-McDonnell Douglas, Pratt & Whitney and General Electric). Phase one of the HSR program started on 1990, and concentrated on the environmental challenges of minimizing NOx and noise. The first program goal is to reduce the NOx emission index to less than 5 (Concord NOx index is 20 and is unacceptable), in order to have little impact on the earth's ozone layer. The second goal is to reduce noise levels to FAR Stage 3 (or better), comparable to those of subsonic aircraft (far below the Concorde noise levels that require exemptions form less stringent standards). This requirement greatly impacts the nozzle design increasing its length and complexity and poses unique sealing challenges. Phase two started in 1993 and initiated work on the technologies required for an economical HSCT. Materials technologies under development include a ceramic-matrix-composite combustion liner, lightweight materials for the nozzle, as well long-life turbomachinery disk and blade alloys. Other required materials are being developed under the DOD-IHPTET program, where there is close cooperation. Economic goals translate into the development of technologies for tri-class service, 5000 nautical mile range aircraft with a ticket price no more than 20% over the subsonic ticket price. The potential market could be as large as 1500 aircraft, according to a Boeing study. Technology alone will not enable this airplane, yet without enabling technologies "on the shelf", it will not occur. The HSCT engine will be the largest engine ever built and operate at maximum conditions for long periods of time posing a number of challenges. The HSR engine mission requires that rotating equipment stay at take-off condition temperatures for hours not minutes per flight. Hence rotating equipment and seals must operate for many thousands of hours at extreme temperatures. It is anticipated that the nozzle will be 12 feet long and roughly 4 ft. by 5 ft. in cross-section with a nominal airflow of 800 lbs/sec. The complex function of the nozzle (including an ejector for noise attenuation) combined with long life place new demands on nozzle seal design. Three inlet configurations are under consideration with attendant sealing challenges, as will be illustrated herein. Four of these engines are required to propel a 5000 nautical mile class vehicle which demand that component reliability be at the highest possible level. In response, an HSR seals session was implemented as a part of the 1997-Seals and Secondary Flow Workshop. Overview presentations were given for each of the following areas: inlet, turbomachinery, combustor and nozzle. The HSCT seal issues center on durability and efficiency of rotating equipment seals (including brush seals), structural seals (including rope seals and other advanced concepts), and high-speed bearing and sump seals. Tighter clearances, propulsion system size and thermal requirements represent extremes that challenge the component designers. This document provides an initial step toward defining HSR seal needs. The overview for HSR seal designs includes, defining seal objectives, summarizing sealing and materials requirements, presenting relevant seal cross-sections, and identifying technology needs for the HSR office.

Description: Results of a numerical analysis evaluating the feasibility of high-temperature shape memory alloys (HTSMA) for active clearance control actuation in the high-pressure turbine section of a modern turbofan engine has been conducted. The prototype actuator concept considered here consists of parallel HTSMA wires attached to the shroud that is located on the exterior of the turbine case. A transient model of an HTSMA actuator was used to evaluate active clearance control at various operating points in a test bed aircraft engine simulation. For the engine under consideration, each actuator must be designed to counteract loads from 380 to 2000 lbf and displace at least 0.033 in. Design results show that an actuator comprised of 10 wires 2 in. in length is adequate for control at critical engine operating points and still exhibit acceptable failsafe operability and cycle life. A proportional-integral-derivative (PID) controller with integrator windup protection was implemented to control clearance amidst engine transients during a normal mission. Simulation results show that the control system exhibits minimal variability in clearance control performance across the operating envelope. The final actuator design is sufficiently small to fit within the limited space outside the high-pressure turbine case and is shown to consume only small amounts of bleed air to adequately regulate temperature.

Description: The usage and integrated vehicle health management of the NASA C-17. Propulsion health management flight objectives for the aircraft include mapping of the High Pressure Compressor in order to calibrate a Pratt and Whitney engine model and the fusion of data collected from existing sensors and signals to develop models, analysis methods and information fusion algorithms. An additional health manage flight objective is to demonstrate that the Commercial Modular Aero-Propulsion Systems Simulation engine model can successfully execute in real time onboard the C-17 T-1 aircraft using engine and aircraft flight data as inputs. Future work will address aircraft durability and aging, airframe health management, and propulsion health management research in the areas of gas path and engine vibration.

Description: The goal of doubling thrust-to-weight ratio for gas turbine engines has placed significant demands on engine component materials. Operating temperatures for static seals in the transition duct and turbine sections for instance, may well reach 2000 F within the next ten years. At these temperatures conventional age-hardenable superalloys lose their high strength via overaging and eventual dissolution of the gamma precipitate, and are well above their oxidation stability limit. Conventional solid-solution-strengthened alloys offer metallurgical stability, but suffer from rapid oxidation and little useful load bearing strength. Ceramic materials can theoretically be used at these temperatures, but manufacturing processes are in the developmental stages.

Description: This viewgraph presentation describes the effects of compression, staging and braid angle on braided rope seals. The contents include: 1) Test Fixture Schematics; 2) Comparison of Hybrid Seal Braid Architecture; 3) Residual Interference After Compression Cycling; 4) Effect of Compression, Braid, and Staging on Seal Flow; 5) Effect of Staging on Seal Pressure Drop; 6) Three Stag Seal Durability; 7) P&W Turbine Vane Seal Requirements; and 8) Next Generation Fighter F-22 P&W F119 Engines.

Description: It is common practice to use Pre-Swirl Nozzles to facilitate getting the turbine blade cooling air onboard the rotating disk with minimum pressure loss and reduced temperature. Higher engine OPR's and expanded aircraft operating envelopes have pushed cooling air temperatures to the limits of current disk materials and are stressing the capability to cool the blade with practical levels of cooling air flow. Providing 'Cooled' Cooling Air is one approach being considered to overcome these limitations. This presentation looks at how the introduction of 'Cooled' Cooling Air impacts the design of the Pre-Swirl Nozzles, specifically in relation to the radial location of the nozzles.

Description: The LM2500+ industrial aeroderivative gas turbine, a 25% enhanced power derivative of the LM2500 gas turbine, recently completed its development test program during the period 5/96 - 10/96. Early in the engine program a Quality Function Deployment (QFD) process was used to determine customer needs for this project.The feedback obtained from the QFD process showed without doubt that gas turbine customers now emphasize product reliability and availability at the top of their needs. One area of development on the LM2500+ was to investigate the use of a brush seal as a means to reduce undesirable turbine cooling leakages within the turbine mid frame in order to enhance part life. This presentation presents a case study on the factors that went into evaluating a brush seal during engine test, test results, and the ultimate decision not to implement the brush seal for cost and other reasons.

Description: Detailed information of the flow-fields in the secondary flowpaths and their interaction with the primary flows in gas turbine engines is necessary for successful designs with optimized secondary flow streams. Present work is focused on the development of a simulation methodology for coupled time-accurate solutions of the two flowpaths. The secondary flowstream is treated using SCISEAL, an unstructured adaptive Cartesian grid code developed for secondary flows and seals, while the mainpath flow is solved using TURBO, a density based code with capability of resolving rotor-stator interaction in multi-stage machines. An interface is being tested that links the two codes at the rim seal to allow data exchange between the two codes for parallel, coupled execution. A description of the coupling methodology and the current status of the interface development is presented. Representative steady-state solutions of the secondary flow in the UTRC HP Rig disc cavity are also presented.

Description: Efforts are in progress to develop advanced sealing for large utility industrial gas turbine engines (combustion turbines). Such seals have been under developed for some time for aero gas turbines. It is desired to transition this technology to combustion turbines. Brush seals, film riding face and circumferential seals, and other dynamic and static sealing approaches are being incorporated into gas turbines for aero applications by several engine manufacturers. These seals replace labyrinth or other seals with significantly reduced leakage rates. For utility industrial gas turbines, leakage reduction with advanced sealing can be even greater with the enormous size of the components. Challenges to transitioning technology include: extremely long operating times between overhauls; infrequent but large radial and axial excursions; difficulty in coating larger components; and maintenance, installation, and durability requirements. Advanced sealing is part of the Advanced Turbine Systems (ATS) engine development being done under a cooperative agreement between Westinghouse and the US Department of Energy, Office of Fossil Energy. Seal development focuses on various types of seals in the 501ATS engine both at dynamic and static locations. Each development includes rig testing of candidate designs and subsequent engine validation testing of prototype seals. This presentation gives an update of the ongoing ATS sealing efforts with special emphasis on brush seals.

Description: Market forces are driving industry to reproduce product cycle time (the time required to conceive, design, build, test, validate and deliver a product). Application of existing tools in new areas can reduce the time required to design a new product and increase the confidence of acceptable test results later in the expensive testing and validation phase. Finite element methods, computational fluid dynamics codes and sharing of CAD datasets when applied to the design of engine externals can provide methods for product improvement and expedited delivery to the customer.

Description: As part of a general investigation of propellers at high forward speeds, tests of two 2-blade propellers having the NACA 4-(3)(8)-03 and NACA 4-(3)(8)-45 blade designs have been made in the Langley 8-foot high-speed tunnel through a range of blade angle from 20 degrees to 60 degrees for forward Mach numbers from 0.165 to 0.725 to establish in detail the changes in propeller characteristics due to compressibility effects. These propellers differed primarily only in blade solidity, one propeller having 50 percent and more solidity than the other. Serious losses in propeller efficiency were found as the propeller tip Mach number exceeded 0.91, irrespective of forward speed or blade angle. The magnitude of the efficiency losses varied from 9 percent to 22 percent per 0.1 increase in tip Mach number above the critical value. The range of advance ratio for peak efficiency decreased markedly with increase of forward speed. The general form of the changes in thrust and power coefficients was found to be similar to the changes in airfoil lift coefficient with changes in Mach number. Efficiency losses due to compressibility effects decreased with increase of blade width. The results indicated that the high level of propeller efficiency obtained at low speeds could be maintained to forward sea-level speeds exceeding 500 miles per hour.

Description: An investigation has been made to explore the possibilities of axial-flow compressors operating with supersonic velocities into the blade rows. Preliminary calculations showed that very high pressure ratios across a stage, together with somewhat increased mass flows, were apparently possible with compressors which decelerated air through the speed of sound in their blading. The first phase of the investigation was the development of efficient supersonic diffusers to decelerate air through the speed of sound. The present report is largely a general discussion of some of the essential aerodynamics of single-stage supersonic axial-flow compressors. As an approach to the study of supersonic compressors, three possible velocity diagrams are discussed briefly. Because of the encouraging results of this study, an experimental single-stage supersonic compressor has been constructed and tested in Freon-12. In this compressor, air decelerates through the speed of sound in the rotor blading and enters the stators at subsonic speeds. A pressure ratio of about 1.8 at an efficiency of about 80 percent has been obtained.

Description: Sound pressure levels, frequency spectrum, and jet velocity profiles are presented for an engine-afterburner combination at various values of afterburner fuel - air ratio. At the high fuel-air ratios, severe low-frequency resonance was encountered which represented more than half the total energy in the sound spectrum. At similar thrust conditions, lower sound pressure levels were obtained from a current fighter air craft with a different afterburner configuration. The lower sound pressure levels are attributed to resonance-free afterburner operation and thereby indicate the importance of acoustic considerations in afterburner design.

Description: Damaged aircraft have occasionally had to rely solely on thrust to maneuver as a consequence of losing hydraulic power needed to operate flight control surfaces. The lack of successful landings in these cases inspired research into more effective methods of utilizing propulsion-only control. That research demonstrated that one of the major contributors to the difficulty in landing is the slow response of the engines as compared to using traditional flight control. To address this, research is being conducted into ways of making the engine more responsive under emergency conditions. This can be achieved by relaxing controller limits, adjusting schedules, and/or redesigning the regulators to increase bandwidth. Any of these methods can enable faster response at the potential expense of engine life and increased likelihood of stall. However, an example sensitivity analysis revealed a complex interaction of the limits and the difficulty in predicting the way to achieve the fastest response. The sensitivity analysis was performed on a realistic engine model, and demonstrated that significantly faster engine response can be achieved compared to standard Bill of Material control. However, the example indicates the need for an intelligent approach to controller limit adjustment in order for the potential to be fulfilled.

Description: The research in Supersonic Cruise Efficiency Propulsion (SCE-P) Technical Challenge area of NASA's Supersonics project is discussed. The research in SCE-P is being performed to enable efficient supersonic flight over land. Research elements in this area include: Advance Inlet Concepts, High Performance/Wider Operability Fan and Compressor, Advanced Nozzle Concepts, and Intelligent Sensors/Actuators. The research under each of these elements is briefly discussed.

Description: Meeting NASA's N+3 goals requires a fundamental shift in approach to aircraft and engine design. Material and design improvements allow higher pressure and higher temperature core engines which improve the thermal efficiency. Propulsive efficiency, the other half of the overall efficiency equation, however, is largely determined by the fan pressure ratio (FPR). Lower FPR increases propulsive efficiency, but also dramatically reduces fan shaft speed through the combination of larger diameter fans and reduced fan tip speed limits. The result is that below an FPR of 1.5 the maximum fan shaft speed makes direct drive turbines problematic. However, it is the low pressure ratio fans that allow the improvement in propulsive efficiency which, along with improvements in thermal efficiency in the core, contributes strongly to meeting the N+3 goals for fuel burn reduction. The lower fan exhaust velocities resulting from lower FPRs are also key to meeting the aircraft noise goals. Adding a gear box to the standard turbofan engine allows acceptable turbine speeds to be maintained. However, development of a 50,000+ hp gearbox required by fans in a large twin engine transport aircraft presents an extreme technical challenge, therefore another approach is needed. This paper presents a propulsion system which transmits power from the turbine to the fan electrically rather than mechanically. Recent and anticipated advances in high temperature superconducting generators, motors, and power lines offer the possibility that such devices can be used to transmit turbine power in aircraft without an excessive weight penalty. Moving to such a power transmission system does more than provide better matching between fan and turbine shaft speeds. The relative ease with which electrical power can be distributed throughout the aircraft opens up numerous other possibilities for new aircraft and propulsion configurations and modes of operation. This paper discusses a number of these new possibilities. The Boeing N2 hybrid-wing-body (HWB) is used as a baseline aircraft for this study. The two pylon mounted conventional turbofans are replaced by two wing-tip mounted turboshaft engines, each driving a superconducting generator. Both generators feed a common electrical bus which distributes power to an array of superconducting motor-driven fans in a continuous nacelle centered along the trailing edge of the upper surface of the wing-body. A key finding was that traditional inlet performance methodology has to be modified when most of the air entering the inlet is boundary layer air. A very thorough and detailed propulsion/airframe integration (PAI) analysis is required at the very beginning of the design process since embedded engine inlet performance must be based on conditions at the inlet lip rather than freestream conditions. Examination of a range of fan pressure ratios yielded a minimum Thrust-specific-fuel-consumption (TSFC) at the aerodynamic design point of the vehicle (31,000 ft /Mach 0.8) between 1.3 and 1.35 FPR. We deduced that this was due to the higher pressure losses prior to the fan inlet as well as higher losses in the 2-D inlets and nozzles. This FPR is likely to be higher than the FPR that yields a minimum TSFC in a pylon mounted engine. 1

Description: COMBUSTOR and CNOISE are computer codes that predict far-field noise that originates in the combustors of modern aircraft turbine engines -- especially modern, low-gaseous-emission engines, the combustors of which sometimes generate several decibels more noise than do the combustors of older turbine engines. COMBUSTOR implements an empirical model of combustor noise derived from correlations between engine-noise data and operational and geometric parameters, and was developed from databases of measurements of acoustic emissions of engines. CNOISE implements an analytical and computational model of the propagation of combustor temperature fluctuations (hot spots) through downstream turbine stages. Such hot spots are known to give rise to far-field noise. CNOISE is expected to be helpful in determining why low-emission combustors are sometimes noisier than older ones, to provide guidance for refining the empirical correlation model embodied in the COMBUSTOR code, and to provide insight on how to vary downstream turbinestage geometry to reduce the contribution of hot spots to far-field noise.

Description: An experimental investigation was conducted to determine the cooling effectiveness of a wide variety of air-cooled turbine-blade configurations. The blades, which were tested in the turbine of a - commercial turbojet engine that was modified for this investigation by replacing two of the original blades with air-cooled blades located diametrically opposite each other, are untwisted, have no aerodynamic taper, and have essentially the same external profile. The cooling-passage configuration is different for each blade, however. The fabrication procedures were varied and often unique. The blades were fabricated using methods most suitable for obtaining a small number of blades for use in the cooling investigations and therefore not all the fabrication procedures would be directly applicable to production processes, although some of the ideas and steps might be useful. Blade shells were obtained by both casting and forming. The cast shells were either welded to the blade base or cast integrally with the base. The formed shells were attached to the base by a brazing and two welding methods. Additional surface area was supplied in the coolant passages by the addition of fins or tubes that were S-brazed. to the shell. A number of blades with special leading- and trailing-edge designs that provided added cooling to these areas were fabricated. The cooling effectiveness and purposes of the various blade configurations are discussed briefly.

Description: A wide range of rocket propulsion test work occurs at the NASA John C. Stennis Space Center (SSC) including full-scale engine test activities at test facilities A-1, A-2, B-1 and B-2 as well as combustion device research and development activities at the E-Complex (E-1, E-2, E-3 and E-4) test facilities. The propulsion test engineer at NASA SSC faces many challenges associated with designing and operating a test facility due to the extreme operating conditions (e.g., cryogenic temperatures, high pressures) of the various system components and the uniqueness of many of the components and systems. The purpose of this paper is to briefly describe the NASA SSC Engineering Science Directorate s design and analysis processes, experience, and modeling techniques that are used to design and support the operation of unique rocket propulsion test facilities.

Description: Electrodynamic propulsion based on the interaction of a conducting tether with the background magnetic field can be implemented across a range of system designs. Bare tethers, bare and insulated tethers with a balloon termination, and insulated tethers with a grid-sphere termination have been proposed for different applications. Electrodynamic tether as a thruster is currently proposed for the Momentum exchange Electrodynamic Reboost (MXER) Tether System that currently under development at NASA Marshal Space Flight Center. The choice of a tether design for a specific mission is based on the analysis of tether system performance. Different parameters describing tether performance such as system acceleration and efficiency can be calculated if the current distribution along the tether at the satellite trajectory is known. The code calculating the tether current collection for the bare and partly insulated tethers with the circular (wire) and rectangular (tape) cross-sections operating in the thrust mode has been developed and applied for MXER that is expected to operate in an equatorial elliptical orbit with perigee in the altitude range of 300-500km and apogee between 5000-8000km. The collected current is calculated as a function of the satellite velocity and the Earth s magnetic field, plasma parameters (plasma density and temperature), and tether parameters (tether length, the length of the bare segment, the type and the dimensions of the cross-section). The deviation of the collected current from the OML model due to the tether thickness and self-induced magnetic field (for tether with a circular cross-section) is taken into account.

Description: Contents: Preliminary notes on the efficiency of propulsion systems; Part I: Propulsion systems with direct axial reaction rockets and rockets with thrust augmentation; Part II: Helicoidal reaction propulsion systems; Appendix I: Steady flow of viscous gases; Appendix II: On the theory of viscous fluids in nozzles; and Appendix III: On the thrusts augmenters, and particularly of gas augmenters

Description: A retrofit architecture for intelligent turbofan engine control and diagnostics that changes the fan speed command to maintain thrust is proposed and its demonstration in a piloted flight simulator is described. The objective of the implementation is to increase the level of autonomy of the propulsion system, thereby reducing pilot workload in the presence of anomalies and engine degradation due to wear. The main functions of the architecture are to diagnose the cause of changes in the engine s operation, warning the pilot if necessary, and to adjust the outer loop control reference signal in response to the changes. This requires that the retrofit control architecture contain the capability to determine the changed relationship between fan speed and thrust, and the intelligence to recognize the cause of the change in order to correct it or warn the pilot. The proposed retrofit architecture is able to determine the fan speed setting through recognition of the degradation level of the engine, and it is able to identify specific faults and warn the pilot. In the flight simulator it was demonstrated that when degradation is introduced into an engine with standard fan speed control, the pilot needs to take corrective action to maintain heading. Utilizing the intelligent retrofit control architecture, the engine thrust is automatically adjusted to its expected value, eliminating yaw without pilot intervention.

Description: A systematic approach for selecting an optimal suite of sensors for on-board aircraft gas turbine engine health estimation is presented. The methodology optimally chooses the engine sensor suite and the model tuning parameter vector to minimize the Kalman filter mean squared estimation error in the engine s health parameters or other unmeasured engine outputs. This technique specifically addresses the underdetermined estimation problem where there are more unknown system health parameters representing degradation than available sensor measurements. This paper presents the theoretical estimation error equations, and describes the optimization approach that is applied to select the sensors and model tuning parameters to minimize these errors. Two different model tuning parameter vector selection approaches are evaluated: the conventional approach of selecting a subset of health parameters to serve as the tuning parameters, and an alternative approach that selects tuning parameters as a linear combination of all health parameters. Results from the application of the technique to an aircraft engine simulation are presented, and compared to those from an alternative sensor selection strategy.

Description: A high altitude solar powered airship provides the ability to carry large payloads to high altitudes and remain on station for extended periods of time. This study examines applications and background of this type of concept vehicle, reviews the history of high altitude flight and provides a point design analysis. The capabilities and limitations of the airship are demonstrated and possible solutions are proposed. Factors such as time of year, latitude, wind speeds, and payload are considered in establishing the capabilities of the airship. East and west coast operation is evaluated. The key aspect to success of this type of airship is the design and operation of the propulsion and power system. A preliminary propulsion/power system design was produced based on a regenerative fuel cell energy storage system and solar photovoltaic array for energy production. Results on power system requirements for year long operation is presented.

Description: Strain-gages were used to measure blade vibrations causing failures in the third stage of a production 11-stage axial-flow compressor. After the serious third-stage vibration was detected, a series of investigations were conducted with second-stage vane assemblies of varying angles of incidence. Curves presented herein show the effect of varying the angle of incidence of second-stage vane assembly on third-stage rotor-blade vibration amplitude and engine performance. A minimum vibration amplitude was obtained without greatly affecting the engine performance with a second-stage vane assembly of 9deg. greater angle of incidence than the assembly normally furnished with the engine.

Description: An investigation was conducted to determine the effects of water injection on the over-all performance of a modified J33-A-27 turbojet-engine compressor at the design equivalent speed of 11,800 rpm. The water-air ratio by weight was 0.05. With water injection the peak pressure ratio increased 9.0 per- cent, the maximum efficiency decreased 15 percent (actual numerical difference 0.12), and. the maximum total weight flow increased 9.3 percent.

Description: An investigation of the altitude performance characteristics of an Allison J35-A-17 turbojet engines have been conducted in an altitude chamber at the NACA Lewis laboratory. Engine performance was obtained over a range of altitudes from 20,000 to 60,000 feet at a flight Mach number of 0.62 and a range of flight Mach numbers from 0.42 to 1.22 at an altitude of 30,000 feet. The performance of the engine over the range investigated could be generalized up to an altitude of 30,000 feet. Performance of the engine at any flight Mach number in the range investigated can be predicted for those operating condition a t which critical flow exits in the exhaust nozzle with the exception of the variables corrected net thrust, and net-thrust specific fuel consumption.

Description: The compressor from the XT-46 turbine-propeller engine was revised by removing the last two rows of stator blades and by eliminating the interstage leakage paths described in a previous report. With the revised compressor, the flow choking point shifted upstream into the last rotor-blade row but the maximum weight flow was not increased over that of the original compressor. The flow range of the revised compressor was reduced to about two-thirds that obtained with the original compressor. The later stages of the compressor did not produce the design static-pressure increase probably because of excessive boundary-layer build-up in this region. Measurements obtained in the ninth-stage stator showed that the performance up to this station was promising but that the last three stages of the compressor were limiting the useful operating range of the preceding stages. Some modifications in flow-passage geometry and blade settings are believed to be necessary, however, before any major improvements in over-all compressor performance can be obtained.

Description: The power plant from a Mark 25 aerial torpedo was investigated both as a two-stage turbine and as a single-stage modified turbine to determine the effect on overall performance of nozzle size and shape, first-stage rotor-blade configuration, and axial nozzle-rotor running clearance. Performance was evaluated in terms of brake, rotor, and blade efficiencies. All the performance data were obtained for inlet total to outlet static pressure ratios of 8, 15 (design), and 20 with inlet conditions maintained constant at 95 pounds per square inch gage and 1000 F for rotor speeds from approximately 6000 to 18,000 rpm.

Description: An investigation of a decoupler and a controlled-feathering device incorporated with the YT-56A turboprop engine has been made to determine the effectiveness of these devices in reducing the high negative thrust (drag) which accompanies power failure of this type of engine. Power failures were simulated by fuel cut-off, both without either device free to operate, and with each device free to operate singly. The investigation was made through an airspeed range from 50 to 230 mph. It was found that with neither device free to operate, the drag levels realized after power failures at airspeeds above 170 mph would impose vertical tail loads higher than those allowable for the YC-130, the airplane for which the test power package was designed. These levels were reached in approximately one second. The maximum drag realized after power failure was not appreciably altered by the use of the decoupler although the decoupler did put a limit on the duration of the peak drag. The controlled-feathering device maintained a level of essentially zero drag after power failure. The use of the decoupler in the YT-56A engine complicates windmilling air-starting procedures and makes it necessary to place operating restrictions on the engine to assure safe flight at low-power conditions,

Description: A corona discharge device generates an ionic wind and thrust, when a high voltage corona discharge is struck between sharply pointed electrodes and larger radius ground electrodes. The objective of this study was to examine whether this thrust could be scaled to values of interest for aircraft propulsion. An initial experiment showed that the thrust observed did equal the thrust of the ionic wind. Different types of high voltage electrodes were tried, including wires, knife-edges, and arrays of pins. A pin array was found to be optimum. Parametric experiments, and theory, showed that the thrust per unit power could be raised from early values of 5 N/kW to values approaching 50 N/kW, but only by lowering the thrust produced, and raising the voltage applied. In addition to using DC voltage, pulsed excitation, with and without a DC bias, was examined. The results were inconclusive as to whether this was advantageous. It was concluded that the use of a corona discharge for aircraft propulsion did not seem very practical.

Description: The turbo-shaft engine is an important propulsion system used to power vehicles on land, sea, and in the air. As the power plant for many high performance helicopters, the characteristics of the engine and control are critical to proper vehicle operation as well as being the main determinant to overall vehicle performance. When applied to vertical flight, important distinctions exist in the turbo-shaft engine control system due to the high degree of dynamic coupling between the engine and airframe and the affect on vehicle handling characteristics. In this study, the impact of engine control system architecture is explored relative to engine performance, weight, reliability, safety, and overall cost. Comparison of the impact of architecture on these metrics is investigated as the control system is modified from a legacy centralized structure to a more distributed configuration. A composite strawman system which is typical of turbo-shaft engines in the 1000 to 2000 hp class is described and used for comparison. The overall benefits of these changes to control system architecture are assessed. The availability of supporting technologies to achieve this evolution is also discussed.

Description: The effects of hot corrosion pits on low cycle fatigue life and failure modes of the disk superalloy ME3 were investigated. Low cycle fatigue specimens were subjected to hot corrosion exposures producing pits, then tested at low and high temperatures. Fatigue lives and failure initiation points were compared to those of specimens without corrosion pits. Several tests were interrupted to estimate the fraction of fatigue life that fatigue cracks initiated at pits. Corrosion pits significantly reduced fatigue life by 60 to 98 percent. Fatigue cracks initiated at a very small fraction of life for high temperature tests, but initiated at higher fractions in tests at low temperature. Critical pit sizes required to promote fatigue cracking were estimated, based on measurements of pits initiating cracks on fracture surfaces.

Description: The operational characteristics of a J57-P1 turbojet engine have been investigated at altitudes between 15,000 and 66,000 feet in the Lewis altitude wind tunnel. Included in this study is a discussion of fuel nozzle coking, the altitude operating limits with and without the standard engine control, the compressor surge characteristics, and the engine starting and windmilling characteristics. Severe circumferential turbine outlet temperature gradients which occurred at high altitude as a result of fuel nozzle coking were alleviated by the manufacturer's change in the fuel flow divider schedule and in a nozzle gasket material. Compressor air bleed is required to prevent surge of the outboard compressor in the low engine speed region. The maximum altitude at which the engine was operated without the control was about 66,000 feet at 0.8 flight Mach number and at a reduced engine speed to avoid compressor surge; with the engine control in operation, the altitude operating limit is reduced to approximately 59,000 feet. The maximum altitude at which the engine was started was about 40,000 feet.

Description: An investigation to increase the compressor surge-limit pressure ratio of the XJ40-WE-6 turbojet engine at high equivalent speeds was conducted at the NACA Lewis altitude wind tunnel. This report evaluates the compressor modifications which were restricted to (1) twisting rotor blades (in place) to change blade section angles and (2) inserting new stator diaphragms with different blade angles. Such configuration changes could be incorporated quickly and easily in existing engines at overhaul depots. It was found that slight improvements in the compressor surge limit were possible by compressor blade adjustment. However, some of the modifications also reduced the engine air flow and hence penalized the thrust. The use of a mixer assembly at the compressor outlet improved the surge limit with no appreciable thrust penalty.

Description: Preliminary design trades are presented for liquid hydrogen fuel systems for remotely-operated, high-altitude aircraft that accommodate three different propulsion options: internal combustion engines, and electric motors powered by either polymer electrolyte membrane fuel cells or solid oxide fuel cells. Mission goal is sustained cruise at 60,000 ft altitude, with duration-aloft a key parameter. The subject aircraft specifies an engine power of 143 to 148 hp, gross liftoff weight of 9270 to 9450 lb, payload of 440 lb, and a hydrogen fuel capacity of 2650 to 2755 lb stored in two spherical tanks (8.5 ft inside diameter), each with a dry mass goal of 316 lb. Hydrogen schematics for all three propulsion options are provided. Each employs vacuum-jacketed tanks with multilayer insulation, augmented with a helium pressurant system, and using electric motor driven hydrogen pumps. The most significant schematic differences involve the heat exchangers and hydrogen reclamation equipment. Heat balances indicate that mission durations of 10 to 16 days appear achievable. The dry mass for the hydrogen system is estimated to be 1900 lb, including 645 lb for each tank. This tank mass is roughly twice that of the advanced tanks assumed in the initial conceptual vehicle. Control strategies are not addressed, nor are procedures for filling and draining the tanks.

Description: NASA Dryden Flight Research Center is a world-class flight research facility located at Edwards AFB, CA. With access to a 44 sq. mile dry lakebed and 350 testable days per year, it is the ideal location for flight research. DFRC has been undertaking aircraft research for approximately six decades including the famous X-aircraft (X-1 through X-48) and many science and exploration platforms. As part of this impressive heritage, DFRC has garnered more hours of full-sized electric aircraft testing than any other facility in the US, and possibly the world. Throughout the 80 s and 90 s Dryden was the home of the Pathfinder, Pathfinder Plus, and Helios prototype solar-electric aircraft. As part of the ERAST program, these electric aircraft achieved a world record 97,000 feet altitude for propeller-driven aircraft. As a result of these programs, Dryden s staff has collected thousands of man-hours of electric aircraft research and testing. In order to better answer the needs of the US in providing aircraft technologies with lower fuel consumption, lower toxic emissions (NOx, CO, VOCs, etc.), lower greenhouse gas (GHG) emissions, and lower noise emissions, NASA has engaged in cross-discipline research under the Aeronautics Research Mission Directorate (ARMD). As a part of this overall effort, Mark Moore of LaRC has initiated a cross-NASA-center electric propulsion working group (EPWG) to focus on electric propulsion technologies as applied to aircraft. Electric propulsion technologies are ideally suited to overcome all of the obstacles mentioned above, and are at a sufficiently advanced state of development component-wise to warrant serious R&D and testing (TRL 3+). The EPWG includes participation from NASA Langley Research Center (LaRC), Glenn Research Center (GRC), Ames Research Center (ARC), and Dryden Flight Research Center (DFRC). Each of the center participants provides their own unique expertise to support the overall goal of advancing the state-of-the-art in aircraft electric propulsion technologies. DFRC will leverage its vast experience in flight test to assist in the integration and flight test phases of any electric propulsion program. DFRC s core competencies, that have particular relevance to the goals of the EPWG, include flight research planning and execution and providing aircraft test beds for researching and testing electric propulsion concepts and equipment. There are three flight regimes that the EPWG is focusing on: subsonic small GA and UAV, subsonic transport class, and supersonic. DFRC proposes two classes of test bed aircraft, to answer the early- and mid-phase testing requirements of all flight regimes the EPWG is concerned with. First, a highly efficient PIK motor glider will be used to test concepts and equipment associated with the subsonic GA and UAV aircraft regime (N+1). Second, a small fleet of subscale remotely-piloted aircraft test beds, similar to the X48B Blended Wing Body aircraft tested at Dryden, will be developed to answer the unique testing requirements of the subsonic GA and UAV, subsonic transport and possibly the supersonic class of aircraft (N+2, N+3). These aircraft can be tested in either serial stages or concurrent stages, depending on the actual test requirements and program schedules. Both classes of test bed aircraft are described below.

Description: A vane has an airfoil shell and a spar within the shell. The vane has an outboard shroud at an outboard end of the shell and an inboard platform at an inboard end of the shell. The spar has a first chamber essentially along the suction side and a second chamber along the pressure side opposite the first chamber.

Description: Key aspects of the design of sealing systems for On Rotor Combustion/Wave Rotor (ORC/WR) systems were addressed. ORC/WR systems generally fit within a broad class of pressure gain Constant Volume Combustors (CVCs) or Pulse Detonation Combustors (PDCs) which are currently being considered for use in many classes of turbine engines for dramatic efficiency improvement. Technology readiness level of this ORC/WR approaches are presently at 2.0. The results of detailed modeling of an ORC/WR system as applied to a regional jet engine application were shown to capture a high degree of pressure gain capabilities. The results of engine cycle analysis indicated the level of specific fuel consumption (SFC) benefits to be 17 percent. The potential losses in pressure gain due to leakage were found to be closely coupled to the wave processes at the rotor endpoints of the ORC/WR system. Extensive investigation into the sealing approaches is reported. Sensitivity studies show that SFC gains of 10 percent remain available even when pressure gain levels are highly penalized. This indicates ORC/WR systems to have a high degree of tolerance to rotor leakage effects but also emphasizes their importance. An engine demonstration of an ORC/WR system is seen as key to progressing the TRL of this technology. An industrial engine was judged to be a highly advantageous platform for demonstration of a first generation ORC/WR system. Prior to such a demonstration, the existing NASA pressure exchanger wave rotor rig was identified as an opportunity to apply both expanded analytical modeling capabilities developed within this program and to identify and fix identified leakage issues existing within this rig. Extensive leakage analysis of the rig was performed and a detailed design of additional sealing strategies for this rig was generated.

Description: Computational fluid dynamics (CFD) analysis has been performed to study the plume effects on sonic boom signature for isolated nozzle configurations. The objectives of these analyses were to provide comparison to past work using modern CFD analysis tools, to investigate the differences of high aspect ratio nozzles to circular (axisymmetric) nozzles, and to report the effects of underexpanded nozzle operation on boom signature. CFD analysis was used to address the plume effects on sonic boom signature from a baseline exhaust nozzle. Near-field pressure signatures were collected for nozzle pressure ratios (NPRs) between 6 and 10. A computer code was used to extrapolate these signatures to a ground-observed sonic boom N-wave. Trends show that there is a reduction in sonic boom N-wave signature as NPR is increased from 6 to 10. The performance curve for this supersonic nozzle is flat, so there is not a significant loss in thrust coefficient as the NPR is increased. As a result, this benefit could be realized without significant loss of performance. Analyses were also collected for a high aspect ratio nozzle based on the baseline design for comparison. Pressure signatures were collected for nozzle pressure ratios from 8 to 12. Signatures were nearly twice as strong for the two-dimensional case, and trends also show a reduction in sonic boom signature as NPR is increased from 8 to 12. As low boom designs are developed and improved, there will be a need for understanding the interaction between the aircraft boat tail shocks and the exhaust nozzle plume. These CFD analyses will provide a baseline study for future analysis efforts.

Description: Helicopter Health Usage Monitoring Systems (HUMS) have potential for providing data to support increasing the service life of a dynamic mechanical component in the transmission of a helicopter. Data collected can demonstrate the HUMS condition indicator responds to a specific component fault with appropriate alert limits and minimal false alarms. Defining thresholds for specific faults requires a tradeoff between the sensitivity of the condition indicator (CI) limit to indicate damage and the number of false alarms. A method using Receiver Operating Characteristic (ROC) curves to assess CI performance was demonstrated using CI data collected from accelerometers installed on several UH60 Black Hawk and AH64 Apache helicopters and an AH64 helicopter component test stand. Results of the analysis indicate ROC curves can be used to reliably assess the performance of commercial HUMS condition indicators to detect damaged gears and bearings in a helicopter transmission.

Description: Flaps (or half wedges) attached to the sides of a pylon are shown to result in a small but clear noise benefit. Noise radiated towards the ground is reduced apparently through a deflection and thickening of the fan stream underneath. Based on results from the current as well as concurrent investigations at the University of California at Irvine, it is recommended that further tests in a larger facility simulating realistic engine conditions be considered.

Description: The primary objectives of this study were 1) to demonstrate that contour plots could be made using the data interface in the NASA GRC jet-in-crossflow (JIC) spreadsheet, and 2) to investigate the suitability of using superposition for the case of opposed rows of jets with their centerlines in-line. The current report is similar to NASA/TM-2005-213137 but the "basic" effects of a confined JIC that are shown in profile plots there are shown as contour plots in this report, and profile plots for opposed rows of aligned jets are presented here using both symmetry and superposition models. Although superposition was found to be suitable for most cases of opposed rows of jets with jet centerlines in-line, the calculation procedure in the JIC spreadsheet was not changed and it still uses the symmetry method for this case, as did all previous publications of the NASA empirical model.

Description: The objective is to provide turbine-cooling technologies to meet Propulsion 21 goals related to engine fuel burn, emissions, safety, and reliability. Specifically, the GE Aviation (GEA) Advanced Turbine Cooling and Thermal Management program seeks to develop advanced cooling and flow distribution methods for HP turbines, while achieving a substantial reduction in total cooling flow and assuring acceptable turbine component safety and reliability. Enhanced cooling techniques, such as fluidic devices, controlled-vortex cooling, and directed impingement jets, offer the opportunity to incorporate both active and passive schemes. Coolant heat transfer enhancement also can be achieved from advanced designs that incorporate multi-disciplinary optimization of external film and internal cooling passage geometry.

Description: The objective of the Advanced Turbine Cooling and Thermal Management program is to develop intelligent control and distribution methods for turbine cooling, while achieving a reduction in total cooling flow and assuring acceptable turbine component safety and reliability. The program also will develop embedded sensor technologies and cooling system models for real-time engine diagnostics and health management. Both active and passive control strategies will be investigated that include the capability of intelligent modulation of flow quantities, pressures, and temperatures both within the supply system and at the turbine component level. Thermal management system concepts were studied, with a goal of reducing HPT blade cooling air supply temperature. An assessment will be made of the use of this air by the active clearance control system as well. Turbine component cooling designs incorporating advanced, high-effectiveness cooling features, will be evaluated. Turbine cooling flow control concepts will be studied at the cooling system level and the component level. Specific cooling features or sub-elements of an advanced HPT blade cooling design will be downselected for core fabrication and casting demonstrations.

Description: For the Intelligent Engine System (Propulsion 21) study, each technology was evaluated to determine the impact to fuel burn, acoustics, and NOx emissions. The optimum combination of technologies and their overall benefits to the system were also evaluated, resulting in noise improvement potential of 1.89 EPNdB cumulative margin,-1.34 percent fuel burn, and 50 percent NOx reduction from the 2015 UEET-QAT baseline. All the technology evaluations, except T18-20D, were based on newengines, where the engine was resized to obtain the maximum system benefit while maintaining the same cycle parameters as the 2015 UEET-QAT baseline. The impact of turbine clearance control on deteriorated engines, T18-20D, was also evaluated. Recommendations for future system study work include, but were not limited to, validation of a university-developed engine deterioration model and customer value analysis as figures of merit beside fuel burn, emissions, and acoustics.

Description: An adaptive controls method for instability suppression in gas turbine engine combustors has been developed and successfully tested with a realistic aircraft engine combustor rig. This testing was part of a program that demonstrated, for the first time, successful active combustor instability control in an aircraft gas turbine engine-like environment. The controls method is called Adaptive Sliding Phasor Averaged Control. Testing of the control method has been conducted in an experimental rig with different configurations designed to simulate combustors with instabilities of about 530 and 315 Hz. Results demonstrate the effectiveness of this method in suppressing combustor instabilities. In addition, a dramatic improvement in suppression of the instability was achieved by focusing control on the second harmonic of the instability. This is believed to be due to a phenomena discovered and reported earlier, the so called Intra-Harmonic Coupling. These results may have implications for future research in combustor instability control.

Description: This document is intended as an introduction to the analysis of gas turbine engine cycles using the Numerical Propulsion System Simulation (NPSS) code. It is assumed that the analyst has a firm understanding of fluid flow, gas dynamics, thermodynamics, and turbomachinery theory. The purpose of this paper is to provide for the novice the information necessary to begin cycle analysis using NPSS. This paper and the annotated example serve as a starting point and by no means cover the entire range of information and experience necessary for engine performance simulation. NPSS syntax is presented but for a more detailed explanation of the code the user is referred to the NPSS User Guide and Reference document (ref. 1).