HyTEC RFI FINAL.pdf

REQUEST FOR INFORMATION (RFI)

80GRC020RFI0001

HYBRID THERMALLY EFFICIENT CORE (HyTEC) PROJECT

1. BACKGROUND

As part of the NASA Advanced Air Vehicles Program (AAVP), a new project is being formulated called Hybrid Thermally Efficient Core (HyTEC) in which NASA intends to collaborate with industry to accelerate the development of small turbofan engine core technologies, culminating in an advanced core demonstration in the 2026 timeframe. The HyTEC goal is to demonstrate increased thermal efficiency with integrated high power-density core engine technologies achieving a 5-10% fuel burn benefit, versus 2020 best in class, for early 2030s entry into service (EIS) single-aisle aircraft. In order to accomplish this, NASA intends to collaborate with industry in a cost sharing arrangement to accelerate technology maturation activities in key areas critical to strengthen the US industry position on small core for a future single aisle aircraft. NASA is seeking additional information from our potential partners that will be used to help with the formulation of the HyTEC project. The information required includes cost, schedule, and technical content. Information obtained from this RFI will help HyTEC make informed decisions on the portfolio investments and acquisition strategy.

NASA has identified a set of technology maturation activities that are candidates for collaboration with industry, where NASA expertise and / or facilities can accelerate industry small core development. These individual technology areas includes: High Pressure Compressor (HPC), High Pressure Turbine (HPT), Combustor, Low Pressure Turbine (LPT), and Turbofan Power Extraction. The first phase of HyTEC will focus on the development of these individual technologies through subsystem or component tests. These efforts will accelerate and mature the needed technologies to Technology Readiness Levels (TRL) of 4-5. The second phase will move toward the core demonstration in which these technologies will be integrated into a full engine core to demonstrate a functional high power-density small core at TRL 6 no later than 2026. NASA would like guidance from industry on critical areas of collaboration in order to focus the HyTEC effort to a few technologies that are best suited for collaboration, in which NASA can offer the most technical benefit to accelerate them with government investment. In addition, Turbofan Power Extraction, an already approved and planned NASA Aeronautics Technical Challenge, will be integrated into HyTEC. The power extraction efforts seeks to achieve 20% power extraction at altitude from a modern commercial turbofan engine with the thrust, efficiency, operability, and durability to enable the benefits of electrified aircraft propulsion at a vehicle level. This work will continue as planned in HyTEC, but NASA wishes to integrate this technology development activity with the small core development. Industry can offer additional perspective on how these two efforts can be more complimentary, showing a path to a future iteration of an engine with hybrid capability using the core technology developed under HyTEC.

NASA is asking for industry to provide information on the technologies being developed by turbine engine manufacturers that align with the NASA plans as described above and provide information for each technology area described in Section 2 to assist the NASA HyTEC planning effort. NASA believes this information will improve the HyTEC project plans, ensuring that the technical content targeted for development is ideal for NASA’s investment and the new small core technology on the next single aisle aircraft achieves maximum fuel burn reduction, durability, and is timely in entry into service.

2. HyTEC TECHNICAL CONTENT

This section briefly outlines the technology areas NASA has identified as candidate areas to collaborate with Industry.

2.1. High Pressure Compressor Technologies

The HPC technology areas listed below seek to address key challenges of small core, high Overall Pressure Ratio (OPR) compressors. As the core size reduces, there is increased losses contributed by tip clearances, blade thickness, cavity flows, and leakage flows which will require technologies to recover the small core losses. Additionally, small cores will put more constraints on the operability and stability of the compressor front block.

Over the last several years, NASA has made significant investments through both in-house and collaborative efforts in loss mitigation strategies. The technologies list below build on the NASA in-house capabilities and expertise.

2.1.1. Front Block Technologies: Improve compressor performance, operability and durability.

2.1.2. Advanced Casing Treatments

2.1.3. Rear Block Technologies: Improve performance and stability.

2.2. High Pressure Turbine Technologies

To achieve an increase in small core thermal efficiency, turbine temperatures will be increased, placing an emphasis on high-temperature material systems and advanced cooling strategies. NASA has been working to understand the aerodynamic, thermal and structural properties of cooled CMC blades. Additionally, NASA is also collaboratively working an effort to understand CMC turbine blade durability. This technologies listed below would leverage NASA facilities and expertise in materials and turbine technology.

2.2.1. CMC Turbine Blade Development

2.2.2. Advanced Cooling Strategies

2.2.3. Advanced Aero Technologies

2.2.4. Advances Materials and Coatings

2.3. Combustor Technologies

Small Core, high OPR engines present greater challenges to combustor emissions and operability. The technology areas below target the development of cooling strategies and compact combustor designs that meet the small core goals without emission penalties.

2.3.1. Advanced Cooling Strategies

2.3.2. Compact Combustor

2.4. Advanced Thermal Management

This technology area spans the entire system of a small core turbofan engine. Advanced compact thermal management systems will need to be in place to increase core thermal efficiency. This work leverages the advanced cooling strategies, additive manufacturing techniques, and innovative design systems.

2.5. Turbofan Power Extraction

The goal of the turbofan power extraction research is to achieve significant power extraction at relevant operating conditions from a modern commercial turbofan engine with thrust, weight, efficiency, operability, and durability to enable the benefits of electrified aircraft propulsion at a vehicle level. Some of the key challenges that this technical challenge seeks to address include: high- and low-spool power extraction split across the mission envelope, mechanical-electrical energy management control, ensuring engine operability, assessing the impact of power extraction on turbomachinery components and overall engine design, performance, fuel burn, weight, and durability.

3. REQUEST FOR INFORMATION

For purposes of this RFI, the HyTEC formulation team seeks information regarding how the private sector may collborativley approach technology maturation activities to achieve TRL 4- 5 by FY 23 and TRL 6 by FY26. The responses should include the following:

3.1. Technology Maturation Approach

3.1.1. Identify the technology maturation areas listed in Section 2 that would be of interest to collaborate in and benefit from a NASA collaboration.

3.1.2. Explain how NASA’s role in the collaboration would either accelerate or enhance the technology development and small core demonstration. It is recommended to identify any key priority technology areas.

3.1.3. If there are technologies not listed in section 2 that you feel could be accelerated to a small core demonstration with help from NASA, please identify and explain the need and benefit of collaboration.

3.1.4. The linkage between Power Extraction and the integration of hybrid electric technologies into the small core demonstration is a very important area that NASA wishes our potential partners to illustrate. NASA is requesting information whether a small core demonstration can include power extraction technology for an integrated test, or if demonstrating power extraction separately is the preferred approach with justification for either position.

3.1.5. HyTEC’s plan is to invest in turbofan engine small core technology development through component or rig tests. The technologies would then be integrated in an advanced high power-density core demonstration. NASA has interest outside of HyTEC to collaborate with industry on advanced fan technology as part of a future single-aisle class engine. NASA is requesting information whether a small core demonstration can be combined with advanced fan technology to demonstrate a full engine, or if a core only demonstration is desired by our potential partners as part of HyTEC.

3.1.6. Section 1 describes the HyTEC performance goals. NASA requests any comments on how this aligns with Industry performance goals and metrics. Provide any other metrics that should be included, for instance, reduced operating costs.

3.1.7. Identify key Industry risks to the technology development and core demonstration test program.

3.2. Schedule

3.2.1. NASA requests a schedule and roadmap of proposed collaborative technology investments showing the progression from the subsystem development to the core demonstration. This schedule would indicate key milestones for technology tests early in the HyTEC project as well as the demonstration. NASA would also request a roadmap that shows TRL progression and the linkage between lower TRL individual technology demonstrations and the full core test.

3.3. Cost

3.3.1. For each technology areas of interest listed in Section 2, NASA requests detailed cost estimates developed separately for each area. As an example, for a specific technology that industry identifies as high importance from Section 2 for collaboration with NASA, a detailed cost estimate for the hardware required to develop that technology through the TRL progression is requested. This would include hardware needed for early development during the TRL 4-5 component or subsystem testing, and any other hardware, rigs, or test costs that may be needed to achieve elevating the technology for inclusion in the core demo.

3.3.2. The core demonstration cost will likely be the largest investment for both NASA and industry. NASA requests a cost estimate for the small core demonstration, including the hardware, facility, or any other costs that would be included in a collaborative contract with the government. Indicate if this demonstration would be a core only or full turbofan demonstration, as well as if power extraction is included in the test.

3.4. Cost Share

3.4.1. For each cost estimate provided, NASA requests a proposed cost share with the government. This cost share should include a breakdown of the investment splits between industry and NASA for hardware, facilities, and any staffing that can be identified at this time. This proposed cost share is not binding for any future contractual agreement, however, NASA does ask for a best effort estimation of the cost share so that the HyTEC formulation team can adequately prioritize and develop budget for the focal technical areas of interest.

3.5. NASA Resources

3.5.1. For each technology area of interest listed in Section 2, NASA requests to identify the NASA resources that would be proposed to be used for developing the technologies. For instance, if NASA expertise will be requested under a collaborative contract for certain research areas; please identify those specific competencies needed. This will allow NASA to estimate the research staff resources to adequately staff HyTEC to meet needs in collaborative technology development arrangements.

3.6. Facilities

3.6.1. For each technology area of interest listed in Section 2, NASA requests that the NASA facilities that would be proposed for testing in each one be identified. If there are existing NASA facilities, test rigs, or laboratories that our potential partners would feel are best suited to develop small core technologies, identifying the facility and estimated duration of use will allow NASA to develop the cost estimate for including those facility costs into HyTEC. Also, if any modifications to any of the NASA facilities are required for small core technologies, please identify those as well which will help in gathering estimates for future capability planning.

3.7 Intellectual Property Rights

3.7.1 For each technology area of interest listed in Section 2, NASA requests that the proposed intellectual property rights position is identified. For instance, what information is proprietary, what information will be limited rights use only for government purposes, and what would be unlimited for publishing and distribution. NASA desires to publish information regarding technologies developed under HyTEC for the broader community so NASA would like to understand the availability of such information.

4. RESPONSES

4.1. Interested parties are requested to respond to the information requested in Section 4.

4.2. Package responses are due no later than 30 September 2020, 6:00 ET. Responses shall submitted via e-mail only to ashlee.b.shaw@nasa.gov and ian.park@nasa.gov.

Submissions may be sent via encrypted e-mail (recommended if proprietary information is included). If so requested in your response, all information received from this RFI will be considered confidential and proprietary. Proprietary and export controlled information should be marked appropriately in your response to the RFI.

4.3. Interested parties are requested to provide the following: Name and address of organization and point of contact (POC) information (name, phone, and e-mail).

4.4. NASA representatives may contact respondants after submittal to clarify any information submitted.

5. INDUSTRY DISCUSSIONS

NASA representatives plan to hold an Industry day to meet with potential offerors. Such discussions would be intended to provide further clarification of the RFI and plans for HyTEC.

6. QUESTIONS

Questions regarding this announcement shall be submitted in writing by e-mail to the Contracting Officer, ashlee.b.shaw@nasa.gov and ian.park@nasa.gov, no later than 6:00pm ET on September 4, 2020. Verbal questions will NOT be accepted. Questions will be answered by email, then at the end of question period all questions and answers will be posted to Beta.Sam; accordingly, questions shall NOT contain proprietary or classified information.

NASA Facilities Reference Sheet

Compressor Facilities:

W-1A: Low Speed Compressor Facility https://www1.grc.nasa.gov/facilities/erb/turbo/#low-speed-compressor-facility-w1a

W-7: Multi-stage Compressor Facility https://www1.grc.nasa.gov/facilities/erb/turbo/#high-speed-multistage-compressor-facility-w7

CE-18: Small engine components compressor test facility https://www1.grc.nasa.gov/facilities/erb/turbo/#small-engine-components-compressor-test-facility-ce18

W-8: Single-stage Axial Compressor Facility https://www1.grc.nasa.gov/facilities/erb/turbo/#singlestage-axial-compressor-facility-w8

Turbine Facilities:

SW-6: Fundamental Film Cooling and Heat Transfer Facility https://www1.grc.nasa.gov/facilities/erb/htf/#fundamental-film-cooling-and-heat-transfer-facility-sw6

CW-22: Transonic Turbine Cascade Facility https://www1.grc.nasa.gov/facilities/erb/htf/#transonic-turbine-blade-cascade-test-facility-cw22

SW-2: Fundamental Turbine Aero and Heat Transfer Facility https://www1.grc.nasa.gov/facilities/erb/htf/#fundamental-turbine-aero-and-heat-transfer-facility-sw2

W-6A: Single Spool Turbine Facility https://www1.grc.nasa.gov/facilities/erb/turbo/#single-spool-turbine-facility-w6a

Dynamic Spin Rig: Link not available Material Labs: Link not available

Combustion Facilities: https://www1.grc.nasa.gov/facilities/erb/#combustor-facilities ASCR: Advanced Subsonic Combustion Rig

CE-5B-1: Sector Combustor Studies SE-5: High Pressure Gaseous Burner SE-11: Particulate Aerosol Laboratory

Altitiude Engine/Driven Rig Test Stands:

Propulsiosn Systems Laboratory:

https://www1.grc.nasa.gov/facilities/psl-3/ https://www.nasa.gov/specials/psl360/

NPR 7123.C Technology Readiness Levels (TRL) Definitions

T R L

Definition Hardware Description

Software Description

Success criteria

Basic principles observed and reported.

Scientific knowledge generated underpinning hardware technology concepts/applications.

Scientific knowledge generated underpinning basic properties of software architecture and mathematical formulation.

Peer reviewed documentation of research underlying the proposed concept/application.

Technology concept and/or application formulated.

Invention begins, practical application is identified but is speculative, no experimental proof or detailed analysis is available to support the conjecture.

Practical application is identified but is speculative; no experimental proof or detailed analysis is available to support the conjecture. Basic properties of algorithms, representations, and concepts defined.

Basic principles coded. Experiments performed with synthetic data.

Documented description of the application/concept that addresses feasibility and benefit.

Analytical and experimental proof-of-concept of critical function and/or characteristics.

Research and development are initiated, including analytical and laboratory studies to validate predictions regarding the technology.

Development of limited functionality to validate critical properties and predictions using non-integrated software components.

Documented analytical/experime ntal results validating predictions of key parameters.

R L

Definition Hardware Description

Software Description

Success criteria

Component and/or breadboard validation in a laboratory environment.

A low fidelity system/component breadboard is built and operated to demonstrate basic functionality in a laboratory environment.

Key, functionality critical software components are integrated and functionally validated to establish interoperability and begin architecture development.

Relevant environments defined and performance in the environment predicted.

Documented test performance demonstrating agreement with analytical predictions.

Documented definition of potentially relevant environment.

Component and/or brassboard validated in a relevant environment.

A medium-fidelity component and/or brassboard, with realistic support elements, is built and operated for validation in a relevant environment so as to demonstrate overall performance in critical areas.

End-to-end software elements implemented and interfaced with existing systems/simulations conforming to target environment. End-to-end software system tested in relevant environment, meeting predicted performance.

Operational environment performance predicted.

Implementations.

Documented test performance demonstrating agreement with analytical predictions.

Documented definition of scaling requirements.

Performance predictions are made for subsequent development phases.

R L

Definition Hardware Description

Software Description

Success criteria

System/sub-system model or prototype demonstration in a relevant environment.

A high-fidelity prototype of the system/subsystems that adequately addresses all critical scaling issues is built and tested in a relevant environment to demonstrate performance under critical environmental conditions.

Prototype implementations of the software demonstrated on full-scale, realistic problems. Partially integrated with existing hardware/software systems. Limited documentation available.

Engineering feasibility fully demonstrated.

Documented test performance demonstrating agreement with analytical predictions.

(End of RFI)