Critical Propulsion Components Volume 1: Summary, Introduction, and Propulsion Systems Studies
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NASA/CR—2005-213584/VOL1 Critical Propulsion Components Volume 1: Summary, Introduction, and Propulsion Systems Studies Pratt & Whitney West Palm Beach, Florida General Electric Aircraft Engines Cincinnati, Ohio May 2005 The NASA STI Program Office . in Profile Since its founding, NASA has been dedicated to • CONFERENCE PUBLICATION. Collected the advancement of aeronautics and space papers from scientific and technical science. The NASA Scientific and Technical conferences, symposia, seminars, or other Information (STI) Program Office plays a key part meetings sponsored or cosponsored by in helping NASA maintain this important role. NASA. The NASA STI Program Office is operated by • SPECIAL PUBLICATION. Scientific, Langley Research Center, the Lead Center for technical, or historical information from NASA’s scientific and technical information. 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Available from NASA Center for Aerospace Information National Technical Information Service 7121 Standard Drive 5285 Port Royal Road Hanover, MD 21076 Springfield, VA 22100 Available electronically at http://gltrs.grc.nasa.gov Abstract Several studies have concluded that a supersonic aircraft, if environmentally acceptable and eco- nomically viable, could successfully compete in the 21st century marketplace. However, before industry can commit to what is estimated as a 15-to-20 billion dollar investment, several barrier issues must be resolved. In an effort to address these barrier issues, NASA and Industry teamed to form the High-Speed Research (HSR) program. As part of this HSR program, the Critical Propulsion Components (CPC) element was created and assigned the task of developing those propulsion com- ponent technologies necessary to: (1) reduce cruise emissions by a factor of 10 and (2) meet the ever-increasing airport noise restrictions with an economically viable propulsion system. The CPC- identified critical components were ultra-low-emission combustors, low-noise/high-performance exhaust nozzles, low-noise fans, and stable/high-performance inlets. Propulsion cycle studies (coor- dinated with NASA–Langley sponsored airplane studies) were conducted throughout this CPC pro- gram to help evaluate candidate components and select the best concepts for the more complex and larger scale research efforts. The propulsion cycle and components ultimately selected were a mixed-flow turbofan (MFTF) engine employing a lean, premixed, prevaporized (LPP) combustor coupled to a two-dimensional mixed compression inlet and a two-dimensional mixer/ejector nozzle. The CPC program began in 1994 and was planned for completion in 2002. Unfortunately, in 1999 NASA chose to prematurely end the HSR program. Although terminated early, the HSR program demonstrated that an economically viable and environmentally acceptable supersonic aircraft (and propulsion system) was achievable. The purpose of this document is to document the CPC findings in support of those visionaries in the future who have the courage to once again pursue a supersonic passenger airplane. Due to the large amount of material presented in this report, it was prepared in four volumes: Volume 1: Section 1 – Summary Section 2 – Introduction Section 3 – Propulsion System Studies Volume 2: Section 4 – Combustor Volume 3: Section 5 – Exhaust Nozzle Volume 4: Section 6 – Inlet Section 7 – Fan/Inlet Acoustic Team NASA/CR—2005-213584/VOL1 iii Table of Contents Page 1.0 Summary. 1 2.0 Introduction. 3 3.0 Propulsion System Studies. 5 3.1 Overview. 5 3.1.1 Program Flow-Down. 5 3.1.2 Propulsion Concepts Considered. 6 3.1.2.1 Propulsion Concept Types. 6 3.1.2.2 Primary Concept Selection. 7 3.1.2.3 First Alternative Concept Selection and Elimination. 7 3.1.2.4 Other Alternative Concepts. 8 3.1.3 Initial Cycle Temperature Selections. 9 3.1.4 System Requirements. 10 3.1.5 System Status Vs Requirements (Final Technology Assessment). 13 3.1.6 Sensitivity Studies. 15 3.1.6.1 Inlet And Combustor Sensitivity Studies. 15 3.1.6.2 Engine Duty Cycle. 22 3.1.6.3 Nozzle Sensitivity Studies. 24 3.1.6.4 Oversized-Fan Study. 33 3.2 Cycle and Flowpath. 37 3.2.1 Technology Concept Aircraft (TCA). 37 3.2.1.1 Engine Study Matrices. 37 3.2.1.2 Updated TCA Definition. 46 3.2.1.3 Cycle Development – TCA. 51 3.2.2 Preliminary Technology Configuration (PTC) Aircraft. 62 3.2.2.1 Wing Planform Studies Leading to PTC Planform Selection. 62 3.2.2.2 Preliminary Technology Configuration (PTC) Definition. 62 3.2.2.3 Sizing the PTC. 64 3.2.2.4 PTC Propulsion System. 66 3.2.2.5 Cycle Development – PTC. 71 3.2.2.6 Flowpath Development – PTC. 75 3.2.3 Technology Configuration (TC) Aircraft. 84 3.2.3.1 Engine Study Matrices. 84 3.2.3.2 System Trade Studies. 87 NASA/CR—2005-213584/VOL1 v Table of Contents (Continued) Page 3.2.3.3 Technology Configuration Design. 90 3.2.3.4 Cycle Development – TC. 93 3.2.3.5 Flowpath Development – TC. 108 3.2.4 Alternate Propulsion Concepts. 116 3.2.4.1 Mid-Tandem Fan. 116 3.2.4.2 VFX/VCF. 124 3.2.5 Product Margins and Requirements. 139 3.2.5.1 Cycle Audit. 139 3.2.5.2 Operability Audit. 140 3.2.5.3 Power and Bleed Extraction. 142 3.2.5.4 Minimum Engine Definition and Hot Day Operation. 142 3.2.6 Numerical Propulsion-System Simulation (NPSS) Modeling Assessment. 152 3.3 Mechanical Design. 152 3.3.1 Temperature, Durability, Manufacturing, and Material Challenges 152 3.3.1.1 Emissions Challenge. 153 3.3.1.2 Noise Challenge. 153 3.3.1.3 Durability Challenge. 153 3.3.1.4 Physical Limitations Challenge. 153 3.3.2 MFTF Mechanical Design Studies (3770.54 Reference Cycle). 155 3.3.2.1 Thrust Balance. 155 3.3.2.2 MFTF3770.54 Fan Aerodynamic and Mechanical Design. 160 3.3.2.3 Compressor Aerodynamic and Mechanical Design. 194 3.3.2.4 Turbine Aerodynamic, Cooling, and Mechanical Design. 201 3.3.2.5 Core Engine Secondary Flow and Rotor Heat Transfer. 219 3.3.2.6 Engine/Nozzle Dynamics and Mount Configurations. 226 3.3.2.7 Controls Architecture and Nacelle Integration. 234 3.3.2.8 Aft Sump and Lube System Design. 237 3.3.3 Technical Requirements of Full-Scale Demonstrator Engine. 241 3.3.4 FLOWPATH Engine Design and Weight-Reduction Studies. 245 3.3.4.1 Early Weight-Reduction Design Studies. 245 3.3.4.2 1998 and 1999 “Ultimate MFTF” Configuration Studies. 253 3.4 New Requirements. 258 3.4.1 Requirements Definition. 258 NASA/CR—2005-213584/VOL1 vi Table of Contents (Concluded) Page 3.4.2 Advanced Concepts Screening. 260 3.4.2.1 Background. 260 3.4.2.2 Concept Screening. 261 3.4.2.3 Concepts Selected. 261 3.4.2.4 Additional Concepts Considered. 263 3.4.2.5 Highly Integrated Concepts. 263 3.4.2.6 Summary. 266 3.4.3 Ultimate MFTF. 266 3.4.4 Ultimate Mixer/Ejector Nozzle. 273 3.4.4.1 General. 273 3.4.4.2 Nozzle Baseline 8/1997. 274 3.4.4.3 Nozzle Components. 275 3.4.4.4 SAVE Event Initiation. 276 3.4.4.5 Single Door Weight Reduction. 276 3.4.4.6 Actuation System Selection. 276 3.4.4.7 Final Baseline (6/1999). ..