't _, I •''

HSR System Integration Studies

NASA Rev{ew of FY92 Progress and FY93 Plans

September 23, 1992

Bill Strack - Lewis

Allen Whitehead - Langley

HIGH-SPEED RESEARCH PROGRAM REVIEW

Propulsion System Studies

Outline

• Phase I Program Milestones

e Propulsion System Study Milestone Plan -- FY92 accomplishments -- FY93 Plans

• Budgets

.'t ..

Major HSCT Propulsion System Issues

1. Which propulsion concept best achieves a balanced compromise of performance, weight, emissions, noise, and complexity ?

2. What price do we pay to achieve various levels of environmental acceptability ?

3. What are the key uncertainties and what are their potential impacts ?

PROPISS.DRW WCS1<'ML 9·10·92

[ HIGH-SPEED RESEARCH PROGRAM . REVIEW )

Propulsion System Studies

Phase I Program Milestones

Propulsion System. ·studies - Lewis Level 2 Summary

Program Milestones

Gross R&D

Net R&D

Research Contracts

Grants

In-House

Program Support

CSWY

SSCWY

FY90

FY90

1580

1t82

1182

0

0

398

7

0

FY91 FY92 FY93

Propulsion System Down-select

Resource Summary (537-01-22)

FY91 FY92 FY93 FY94

2800 3115 1500 1560

2000 2715 1187 1235

1915 2335 1000 1085

85 90 45 0

0 290 142 150

BOO 400 313 325

8 13 12 11

2 2 2 2

FY95

FY95

1620

1282

1122

0

160 .

338

9

2 RESSUMDRW WCS/KML 9-16-92

A Propulsion System Down-Select is Needed to Focus the Phase II Technology Program

Phase I

Environmental Technology Feasibility

~ Concept2

System ~ Studies

• • •

Oct. '93 Down-Select Decision Gate

6 r--I I I I I I I

~oncept])-___ _J __ I

I

Phase II

Propulsion Component

Technologies ~~ Primary ..... Backup

11 System Studies

Monitor Progress - Shortfall impacts - Re-direction options

New concept analyses

6 Technology Readiness

DOWN SEL.DRW WCS/tjf 0801'"'

Level 2 HSR Program Schedule - Propulsion System Studies

HSR Program Milestone

Propulsion Design Studies and Evaluations

Airframer Evaluations

NASA Design Studies and Evaluations

Net R&D, $K

cs +sse wy

FY91 I FY92 I FY93 I FY94 6. Propulsion Down-select

~----------------------------------·~----------~

2000

8+2

~ Life Study Evaluations v Assess. v { II

Ill ~~~~~t:=.:~:~:~:~:~=:II~=:~:I~:~:=:~:~:~:~~I=~~!=~:~;t=~::;=:~\~:[=tl

Common Down-select Engme Engtne Strategies Groundrules Process Data Cost 11

' \. \. ' ' TBE MFTF IFV VCE Flade II

~~~-: Assessment l:f

I I

:----.. I Fallback

2715

13+2

I I

l~il:i:i:!i!!ii!i!i!iiiiii!i~lllliilil!fl.li~~~i~~~~~~~~~~~~~::::::::::::::::::I:l Assessment

I 1500

12+2

Strategies

1560

11 + 2

Note: Funding excludes airframer evaluation element which is funded by airframe system studies SCHEDULDRW WCS1<'ML 9-21-92

HIGH-SPEED RESEARCH PROGRAM REVIEW

Propulsion · System Studies

FY92 Accomplishments

Propulsion System Studies Accomplishments

FY92 Accomplishment

1. Determined benefits of EPM technology

2. Established I implemented down-select process

3. Completed commercial engine life study

4. Performed comparative analyses of alternative concepts

5. Quantified impact of key uncertainties

Significance

Provides quantitative program justification

Foundation of rationale consensus decision

Established design rules and EPM requirements

Critical down-select information

Provides down-select risk insights

PI.ANACCZDRW WCSIKML 9-21-92

HSR Enabling Propulsion Materials Program Benefits 2005 IOC Aircraft meeting Stage 3 noise and EINox = 5 constraints

1991 Engine Materials Technology

Airplane gross weight = 720,000 lb Engine life < 1 000 hours

Metal

Combustor

liner

Max. T3 = 1oso·F

Conventional

Turbomachinery

Materials

Metal

Exhaust

Nozzle

wnh 10% cooling

/ + EPM Program

2000 Engine Materials Technology

+6.5% Cruise Efficiency

-15% Propulsion Weight

-12% Airplane Weight

9,000 - 18,000 hr Engine Life

CMC Combustor

Liner

wnh 14% cooling

Max. T3 = 12so·F

Adv. Nickel

Alloy

lntermetallic Exhaust

Nozzle

with no cooling

/

EMPCL2,.DRW WCS/KML 9-10.92

HSR Propulsion System Selection Process

Cycle Optimization and Preliminary Concept Screening (GE I PW, LeRC}

Candidate ~ Concepts~ 1

TBE VCE MFTF Flade TBE/IFV

I I I I 1 • Performance

Mission Evaluation

1 • Weight I Geometry Common ~ 1 • Acoustics -Groundrules 1 • Cost 1

\..----- --------- fl--------------------.../

Data Decks

-t +Overall Systems Assessment (BAC, DAC, LaRCIARC}

\._J Inlet Matching Airframe Installations (3)

Mission Evaluation } Economic Analysis .. DOC Risk Assessment

I 2 3 4 5

Preferred Concept

APPROAC2.0RW WCS/KML 11-27-91

Monte Carlo Simulation Risk Analysis Inlet, Engine, Nozzle Components Maintenance Cost

Price Weight

Efficiency

Probability

Value

TBE MFTF

VCE FLADE

TBE/IFV

8Qio lito.

~ Confidence so·

' 201o

' DOC

1 1 1 1

Many passes through with::;:::> C random Input values

Propulsion System Models

(5 Concepts)

• DOC

Direct Operating

Cost Model

1 2 3 4 5

~ t=V

Propulsion System Forecast Maintenance Cost

Price Weight

Performance

Confidence

Ifill • Aircraft System Model

SFC

MONTE.DRW WCS/lJL 09/01/'fJ.

Mach 2.4 Turbine ·Bypass Engine Life Study

Design Changes from Military-like ST)949 to HSCT ST)989

T3: 1300 ~ 1250°F

• Engine weight increased -11%

• Engine design groundrules established

• Material requirements identified for achieving life goals (EPM impact)

Limited Distribution

HSCT COMMUNITY NOISE TECHNOLOGY Challenge

Turbojet Engines

Engine exhaust velocity = 3,200 ft/sec

Unsuppressed Sideline Noise

/

\ FAR 36- Stage Ill

123 EPNdB

Throttled Engine and Oversized Wing

......,.,.,...,..,.....,..........,."""' High-Lift

I

Mixer-Ejector Nozzle Suppression System

102.5 EPNdB

I I Stage IV i - - - - - - r - ?

I 1/\/\AAAA.

Status with Gen. I mixer-ejector nozzles and without operational procedure credits

HSCT_2DRW WCS/lJL 08/31/92

Effect of Exhaust Velocity on Sideline Noise

120

110 Sideline Noise, EPNdB

100

1000

-

1500

Flade

Stage3

TJ

20+dB problem

-------------------

2000 2500 3000 .

Exhaust Velocity, ft/s

3500

SIDELINEX.DRW WCS/tp 111/31/92

Status of NASA In-House Comparative Propulsion Studies Mach 2.4, 100% supersonic 5000 n.mi. range, 292 passengers

Stage III sideline constraint Assumes material "goals and mixer-ejector nozzle goals are achieved

LeRC results as of September, 1992

1.15

Relative Takeoff 1· 10

Gross Weight

1.05

1.00

0.95L---TBE MFTF TJ/IFV

- Limited Distribution -

I I I TBD I I I

VCE

I I I TBD I I I

Flade INHOUSE WCSIKML 9-21·92

Key Propulsion . System Uncertainties

Technical

1. Adequate mixer - ejector nozzle aero I acoustic performance -- oversize engine and I or wing -- exclude TBE and low-BPR MFTF

2. EPM materials progress -- investigate alternative shortfall strategies

External

· 3. More severe airport noise regulations -- determine economic penalty -- identify tolerant concepts

4. Climb noise -- determine low climb noise concepts

5. Mach number selection -- focus on 2.4 -- design a few 1.6 and 2.0 engines (sonic boom, emissions,

airframe materials) KEYPROPORW WCS/I(ML 9-14-92

Impact of Noise Suppression ·rechnology and Noise Constraint Mach 2.4, all supersonic 5000 n.mi. range, 292 passengers

Cycle, nozzle, wing loading, thrust loading vary along each curve

Ignores aircraft installation differences and possible climb noise constraint NASA Lewis results as of September 1992

1.15

1.1

Relative Takeoff 1 05 Gross Weight . TJ I IFV

2600°F 2900°F

TBE T 41 = 2100°F

1 ---------------

0.2 0.1 0"95 OL..,..__ ____ 5L.....__ ___ ___J1_0 ___ ---~15 ____ 2__.0 Stage 111

5 1 0 15 2 0 2 5 Stage Ill- 5

Noise Suppression, dB

- Limited Distribution -IMPACf.DRW WCS/.KML 9-14-92

ll TOGW, 0/o

Sensitivity to Nozzle Performance and Weight

Mach 2.4 TBE - Powered HSCT Reference TOGW: 701,000 lb

20

15

10

5

0

-5 .92 .93 .94 .95 .96

Nozzle Cv .97 .98

1.0 1.2 1.4 1.6 Relative Nozzle Weight

.99

SF.N!li11V .IJRW WCS/t~ 117/30/92

Impact of Turbine Inlet Temperature On EINax and TOGW HSR LPP Combustor Technology

6

5

4

3

2

1

-----------0~--~-~---~~----+-----~----~ 2500 2600 2700 2800 2900

~1 ?F

Flame Tube data

3000

Example Fallback Strategies for CMC Combustor Liner Material

Strategy 1. A. Sacrifice life by as much as one-half and replace CMC combustor liners at the 9, 000 hour scheduled replacement of rotating hot parts. Impact: ADOC = +1-114%.

Strategy 2. B. Double the LPP combustor liner cooling flow to retain life. This would double NOx El from 2-1/2 to 5 unless turbine temperature were decreased - 2000F. Impact: A TOGW = +2%.

EPMHSR.DRW WCSIKML 9-15-92

HIGH-SPEED RESEARCH PROGRAM REVIEW

Propulsion System Studies

FY93 Plans

1.

2.

3.

4.

5.

Propulsion System Studies ·Planned Accomplishments

Planned FY93 Accomplishment

Complete propulsion down-select studies including risk assessments

Determine impact of "Stage IV" constraint

Complete turbomachinery noise characterization

Complete climb noise comparisons

Complete Lockheed propulsion installation study

Significance

Provides information required for down-select

Helps thwart arbitrary rule-making Helps select tolerant propulsion concept

Enables . approach noise assessments

Strengthens down-select and FAR 36. assessment

Helps select axi or 2-D nozzles and ·inlets

PLANACCP.DRW WCSIKML 9-21-92

Douglas Propulsion Risk Assessntent Objectives:

1. Define inlet system uncertainties quantitatively 2. Perform overall propulsion system risk assessment for five concepts

100

Probability % 50

DAC

Inlet parameters (P/p, Wgt., .... )

TBE MFTF

VCE FLADE

TBE/IFV

"

+

' 00/ Confidence 50

' 20

" DOC

100

50

1 1 1 1

GE/PW

Engine & nozzle parameters

Stage III &

Stage III-X

OOUGRJSK.DRW WCS/KML 9-14-92

GE I PW Generation II Mixer-Ejector Nozzle Design-Evaluation

Objectives: Evaluate methods of achieving FAR 36 Stage Ill- 4 dB

Amroach: Axi-20 hybrid nozzles - 60% and 80% MFA versions

BPR MFA

.4 105

TOGW .4 60,80 .68 60,80

for Axi~2D:::::::::U:H:::=::n::. MFTF H ··brid\::::::!,)':::?:

Engines .4 ?

- mechanical design and weight - 30 flowpath design - aero and acoustic performance - boat-tail drag

20 SLP nozzle with increased suppression treatment

Oversize

engine

engine engine

acoustic treatment

Case A. Stage Ill

Case B. Stage Ill - 4

GI:N_II.DRW WCSIKML 9· 14·92

HSCT Climb Noise Prediction Task

Obiective: •

Background:

Approach:

Make first-order estimates of climb noise for 5 propulsion concepts assuming deployed suppression systems.

High specific thrust engines may not be able to achieve adequate climb noise levels. Ability to predict acoustics is minimal.

Analytically predict mixer-ejector nozzle performance and acoustics up to Mach 0.7. Accept error band for acoustics.

Region of Concern ,,. _ __,,.._"' _____ , 100

Noise level, 80 dBAMAX

60

40 .__ _ ___,a __ ....;

0 20 40

Unsuppressed TBE-powered HSCT

Suppressed HSCT

60 80

Distance from brake release, n.mi. PREDICT.DRW WCSIKML 9·21·92

Lockheed Propulsion I Airframe Installation Study • Detailed performance determination • Configuration optimization • Axi vs. 2-D nozzle comparison • Axi vs. 2-D inlet comparison

GE VCE Engines and Nozzles Lockheed Airframe and Inlets

Axi

+ 2-D

Status: 65% complete (100% by 12-31-92)

Early result: Wing notch required for inboard diverters WCKHEED.DRW

WCSIKML 9-10-92

HIGH-SPEED RESEARCH PROGRAM REVIEW

Propulsion System Studies

Budgets

FY92 HSR Propulsion Systems Studies Elements Propulsion Portion

FY92 FY93 I I I I I I

Baseline (2365K)

GE I PW Mach 2.4 engines I nozzles

GE I PW Mach 1.6 I 2.0 engines I nozzles

NASA Mach 2.4 engines and support

Augmentation (350K)

GE I PW Gen II M-E nozzle design I Stage Ill - 4 assessment -! DAC inlet risk and system risk assessments

Flade fan aero I mechanical design

Notes: 1. GE I PW and DAC will perform Monte Carlo risk assessments 2. BAC will use traditional risk assessment 3. Stage Ill- x assessments will be performed by DAC, GE I PW, and NASA

Net $K

1200

BOO

365

175

120

55

2715

STDYELEM.DRW WCSf<MI. 9-14·92

HSR Propulsion Systems Studies

Airframe Portion (LaRC administered, LeRC technically monitored)

Mach 2.4

Boeing - TBE, BAC 2D

MFTF (.4, .7, 1.13 BPR)

TBE /IFV

VCE (.4, .26 BPR)

Flade

Detailed evaluations

Douglas and NASA

Boeing - Mach 2.0

Douglas - Mach 1.6

1992 1993 JIFIMIAIMIJI JIAISIOINID JIFIMIAIMIJlJ)AISIOlNlD

.r••~m~~Win1EI b. .A Performance, weight, geometry

b. Cost data mi!f.~nw..l!ru!!ln!:!mlilliM!I~\'lf:!l!lmi!IHn~!!nnmi!IJ1i.ll~ij~~'!llliii!il!li!~

A& D.

~mil

~~,~-~-i.t.l!!!iliiiiiliii1~~H:!.~:~li!ltaU.1dll .A ~

li~fH!l!..llrrli!lll!lll!li!l\llll!!!!iill!l~ .A D.

Similar

~~~\~~'ffi!l!ii!!!il!!!!!ffi[~~~~plli. 1!i1!i !In! !1!1i.'l,llllliill~ll

rtE Fl:e ~FTF 'liilllii!il.illl!lllillliilllll!ilmm~mnl

A A MF1F Flade

.(},Tentative Down-Select

Choices ..(), fi1~l!~ll:l:~~~~~~~~mlll~ll~~~~~~~!llllllml!~llm:~illlllllllllllllllll~ll~l!i~~m~l

I

CONTRACT.DRW WCS'KML 9-15-92

Decision Rationale for FY93 Task Prioritization •

Prioritized Tasks

1. Down-select support for airframers

2. Turbomachinery noise characterization

3. Annual meeting support

4. Cycle and P AI support (LeRC)

5. Flade fan aero I mech. design

6. Climb noise comparisons

7. Mixer-ejector nozzle life study

8. In-depth MFTF core life study

9. EPM fallback strategy analysis

10. Incorporate life models in cost code

Rationale ( ~ = influences down-select)

v Increases fidelity. Insures correct decision.

v Could reveal concept discriminators.

v Conveys key information and forces interpretation.

v Only way for NASA to integrate inlets, engines, nozzles.

v Reduces Flade component uncertainties.

v Deployed suppression systems (M-E) may be show-stopper

Companion to engine life study. Could alter weights.

Reduces risk of wrong material development and IOC delay.

EPM is high-risk and enabling ..

Increases fidelity of DOC calculations.

PRIORITY.DRW WCS/KML 9-15-92

Proposed FY93 HSR Propulsion System Studies Resource Allocation

Baseline Down-Select

Specific 1. Down-select support for airframers V GE!PW

-- cycle I flowpath analyses - risk assessments -- inlet distortion tolerance - inlet flow matching

2. Turbomachinery noise characterization GE/PW during approach

3. Annual meeting support GE!PW

4. Cycle and PAl support " LeRC

5. Flade fan aero I mechanical design " GE

OverguideUne

6. Climb noise comparisons GE/PW

7. Mixer - ejector nozzle life study GE

8. In-depth MFTF core life study P&W

9. EPM fallback strategy analysis GE

RESAUC1.DRW 10. Incorporate life models into engine cost code GE

WCSMML 11-10-92

.,

Net $K 660

220

40

187

80

1187

OGL

85

360

220

440

200

135

FY92

MILESTONE STATUS HIGH-SPEED RESEARCH PROGRAM

RTOP 537-01-22 PROPULSION SYSTEMS STUDIES

Activities

22.1 Propulsion Concepts Assessment

- Refined Mach 2.4 -Mach 1.6 & 2.0 -NASAIH

22.2 Unique Component Modeling - Civil Engine Life &

Material Technology Requirements

- 2D vs. Axllnlat Evaluation and Flada Inlet Evaluation

- 2D vs. Axl Mixer-EJector Nozzle Evaluation and Flada Nozzle Evaluation

1991 1992

Oct I Nov I Dec Jan I Feb I Mar I Apr I May I Jun I Jul I Aug I Sep1

Initial Mach 2.4 · engine evaluaUon

\7 completed

Engine welga. determined & technology

8hortfalla ldenUfled ..... :::::::::: ~::::::::::: ~: ~ =~: ~:: :: =~: ~::: ~: ~ ::::: ~::: ~=:::: ~::: ~ =~::::: ~::::: ~: ~::: ~::::: ~: ::: =~: ~::::: ~: ~=~ .....

Bestul& 2Dconcept aelectlona

::: ~::: ~ =~::::::::::::::::: ~: ~::::::::::: ~::::::::::: ~::::::::::::::::::: ~: ~: ~::::::::: :: ~:::::::: :~:::: :::::: ::::::::::::::::::: =­.....

Ad.va.2D ln8lella8on

_.,... complela

~: ~: ~: ~: ~: ~: ~: ~: ~: ~: ~: ~: ~: ~: ~: ~::: ~::: ~::::::::::: ~: ~: ~: ~::: ~: ~: ~: ~: ~: ~: ~: ~::: ~: ~: ~: ~: ~::: ~: ~::::: ~: ~::: ~: ~::: ~: ~::::: ~::: ~::::: ~::::: ~::::::::: ~: ~: ~::: ~::: ~: ~: ~: ~::: ~: ~: ~: ~: ~: ~::::: ~::: ~: ~: ~: ~: ~: ~: ~: ~: ~:::::: ~ \ ): ~::: ~: ~: ~:: ~1.

KEY \J PLANNED ACTIVITY 0 PLANNED OR INCOMPLETE MILESTONE

+ COMPLETED MILESTONE b. SCHEDULED COMPLETION FOR DELAYED ACTIVITY

• ACTIVITY ACTUAL COMPLETION

.. 1

FY93

MILESTONE STATUS HIGH-SPEED RESEARCH PROGRAM

ATOP 537-01-22 PROPULSION SYSTEMS STUDIES

Activities

22.1 Propulsion Concepts Assessment

22.2 Unique Component Modeling

- Flade fan aero/ mech. design

- Gen. 2 axl and 2D mixer­ejector nozzles (Performance, size, weight & noise)

1992 1993

Oct I Nov I Dec Jan I Feb I Mar I Apr I May I Jun I Jul I Aug I Sep1

Engine decks AlternaUve conet pta available evaluation

\] completed

Fladefan model&rlsk determined

~}!=nn=n==H=!n=u,=u:=!n=~H=!=!=H=nn=H=!==!n==!=i~n°H=:(=y=n==u=nn=ini=nn=wt=:nt=n!=n:!=:n!=:u=nn=n::=nn=nn~n(>

Gen 2 mixer eJector Axl vs. 2 ~ nozzle characlerlsUcs

lnslallaUil ~ determined analysis cotr plete \]

"""=!"":!:!""":!:""!n:"'"'!:i"":in""":i:""in:=:n=:!:!""":!:""!:!:"'"'::!"":i:i"""::::d:~:. "...2."":i:"":n:=in.=,in.,;:!::=n:=:n:.,.,.in:""in=:!n""":!:"":n:=!:::""!n""':HI 1*

Rrstorder lurbomachlnery noise

model completed

- Turbomachlnery noise !:!:i:!:i:::::::::::::::::::::::!:::::::::::::::::::::::::::::::!::::n:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::!l(

Flrslorder climb noise estimates

- Climb noise model ::::;::::::::i:::::::::::=:i:::::::::::::i:::::::::::::::i:::::::::::::::::::::::::::::::::i:::::::::::::::!:::::::::::::::i:i:::::::::::i:=:::::::::::V

*Actlvlly delayed from FY92

KEY '\J PLANNED ACTIVITY 0 PLANNED OR INCOMPLETE MILESTONE

• COMPLETED MILESTONE b. SCHEDULED COMPLEilON FOR DELAYED ACTIVITY

... ACTIVITY ACTUAL COMPLETION 04KLA047 LAN9/22/92

..

Summary

1. Adequate progress towards Oct. '93 down-select

-- process defined and established -- TBE, MFTF's, TJ I IFV data decks generated -- VCE and Flade data decks by Oct. 30th -- pace is manpower limited

2. MFTF more forgiving than TBE to M-E nozzle shortfalls I Stage IV

3. Stage 111-5 causes 3-7% TOGW penalty

4. Moderate hot-section materials shortfalls appear tolerable

5. FY93 plans limited to down-select issues only SUMMARt.DRW WCSIKML 9-15-92