Energy efficient engine high-pressure turbine detailed design report

The energy efficient engine high-pressure turbine is a single stage system based on technology advancements in the areas of aerodynamics, structures and materials to achieve high performance, low operating economics and durability commensurate with commercial service requirements. Low loss performance features combined with a low through-flow velocity approach results in a predicted efficiency of 88.8 for a flight propulsion system. Turbine airfoil durability goals are achieved through the use of advanced high-strength and high-temperature capability single crystal materials and effective cooling management. Overall, this design reflects a considerable extension in turbine technology that is applicable to future, energy efficient gas-turbine engines

A feasibility assessment of magnetic bearings for free-piston Stirling space power converters

This report describes a design and analysis study performed by Mechanical Technology Incorporated (MTI) under NASA Contract NAS3-26061. The objective of the study was to assess the feasibility and efficacy of applying magnetic bearings to free-piston Stirling-cycle power conversion machinery of the type currently being evaluated for possible use in long-term space missions. The study was performed for a 50-kWe Reference Stirling Space Power Converter (RSSPC) system consisting of two 25-kWe free-piston Stirling engine modules. Two different versions of the RSSPC engine modules have been defined under NASA Contract NAS3-25463. These modules currently use hydrostatic gas bearings to support the reciprocating displacer and power piston assemblies. Results of this study show that active magnetic bearings of the attractive electromagnetic type are technically feasible for RSSPC application provided that wire insulation with 60,000-hr life capability at 300 C can be developed for the bearing coils. From a design integration standpoint, both versions of the RSSPC were found to be conceptually amenable to magnetic support of the power piston assembly. However, only one version of the RSSPC was found to be amendable to magnetic support of the displacer assembly. Unacceptable changes to the basic engine design would be required to incorporate magnetic displacer bearings into the second version. Complete magnetic suspension of the RSSPC can potentially increase overall efficiency of the Stirling cycle power converter by 0.53 to 1.4 percent (0.15 to 0.4 efficiency points). Magnetic bearings will also overcome several operational concerns associated with hydrostatic gas bearing systems. However, these advantages are accompanied by a 5 to 8 percent increase in specific mass of the RSSPC, depending on the RSSPC version employed. Additionally, magnetic bearings are much more complex, both mechanically and particularly electronically, than hydrostatic bearings. Accordingly, long-term stability and reliability represent areas of uncertainty for magnetic bearings. Considerable development effort will be required to establish the long-term suitability of these bearings for Stirling space power applications

Automatic Feedback Control of Mechanical Gas Face Seals Via Clearance Control

An approach based on proper orthogonal decomposition and Galerkin projection is presented for developing low-order nonlinear models of the gas film pressure within mechanical gas face seals. A technique is developed for determining an optimal set of global basis functions for the pressure field using data measured experimentally or obtained numerically from simulations of the seal motion. The reduced-order gas film models are shown to be computationally efficient compared to full-order models developed using the conventional semidiscretization methods. An example of a coned mechanical gas face seal in a flexibly mounted stator configuration is presented. Axial and tilt modes of stator motion are modeled, and simulation studies are conducted using different initial conditions and force inputs. The reduced-order models are shown to be applicable to seals operating within a wide range of compressibility numbers, and results are provided that demonstrate the global reduced-order model is capable of predicting the nonlinear gas film forces even with large deviations from the equilibrium clearance

Advanced nickel-hydrogen cell configuration study

Three nickel hydrogen battery designs, individual pressure vessel (IPV), common pressure vessel (CPV), and a bipolar battery module were studied. Weight, system complexity and cost were compared for a satellite operating in a 6 hour, 5600 nautical mile orbit. The required energy storage is 52 kWh. A 25% improvement in specific energy is observed by employing a bipolar battery versus a battery comprised of hundreds of IPV's. Further weight benefits are realized by the development of light weight technologies in the bipolar design

Bonding and adjoining technology: A compilation

This compilation covers NASA and AEC developed techniques covering bonding, brazing, and joining methods and technology

Mechanical capacitor

A new energy storage system (the mechanical capacitor), using a spokeless magnetically levitated composite ring rotor, is described and design formulas for sizing the components are presented. This new system is configured around a permanent magnet (flux biased) suspension which has active servo control in the radial direction and passive control in the axial direction. The storage ring is used as a moving rotor and electronic commutation of the stationary armature coils is proposed. There is no mechanical contact with the rotating spokeless ring; therefore, long life and near zero rundown losses are projected. A 7-kW h system is sized to demonstrate feasibility. A literature review of flywheel energy storage systems is also presented and general formulas are developed for comparing rotor geometries

On-Orbit Compressor Technology Program

A synopsis of the On-Orbit Compressor Technology Program is presented. The objective is the exploration of compressor technology applicable for use by the Space Station Fluid Management System, Space Station Propulsion System, and related on-orbit fluid transfer systems. The approach is to extend the current state-of-the-art in natural gas compressor technology to the unique requirements of high-pressure, low-flow, small, light, and low-power devices for on-orbit applications. This technology is adapted to seven on-orbit conceptual designs and one prototype is developed and tested

Transducer applications, a compilation

The characteristics and applications of transducers are discussed. Subjects presented are: (1) thermal measurements, (2) liquid level and fluid flow measurements, (3) pressure transducers, (4) stress-strain measurements, (5) acceleration and velocity measurements, (6) displacement and angular rotation, and (7) transducer test and calibration methods

Space shuttle OMS helium regulator design and development

Analysis, design, fabrication and design verification testing was conducted on the technological feasiblity of the helium pressurization regulator for the space shuttle orbital maneuvering system application. A prototype regulator was fabricated which was a single-stage design featuring the most reliable and lowest cost concept. A tradeoff study on regulator concepts indicated that a single-stage regulator with a lever arm between the valve and the actuator section would offer significant weight savings. Damping concepts were tested to determine the amount of damping required to restrict actuator travel during vibration. Component design parameters such as spring rates, effective area, contamination cutting, and damping were determined by test prior to regulator final assembly. The unit was subjected to performance testing at widely ranging flow rates, temperatures, inlet pressures, and random vibration levels. A test plan for propellant compatibility and extended life tests is included

Metal-to-ceramic seals for thermionic converters - A literature survey

Metal to ceramic sealing techniques for thermionic converters - literature surve