Professional Documents
Culture Documents
Results in Physics: Sun Je Kim, Yeong Ryeon Kim, Yongha Kim, Myung Ho Kim, Myungsup Lee
Results in Physics: Sun Je Kim, Yeong Ryeon Kim, Yongha Kim, Myung Ho Kim, Myungsup Lee
Results in Physics
journal homepage: www.elsevier.com/locate/rinp
A R T I C L E I N F O A B S T R A C T
Keywords: The IR (Infrared) signature generated from hot sections of the aircraft increases potential to be traced by IR
Turbofan engine detection system and severely reduces aircraft survivability during the mission. Main sources of IR signature are
2D exhaust nozzle high temperature parts of the aircraft and the engine such as exhaust nozzle, jet pipe, rear-fuselage, and exhaust
IR signature
gas plume above 400 ◦ C, and they generate detectable 3 to 5 um wavelength IR signature. The novel 2D engine
C-SiC
CFRP
exhaust nozzle with multiple composite layers is proposed to suppress high temperature IR signature from
behind, in this study. The 2D exhaust nozzle with ellipse-shaped cross-sections with high aspect ratios can
disperse high temperature core gas flow, and can enhance mixing performance with bypass air flow. Thus, this
reduces the exhaust gas plume temperature and masks the engine hot sections from behind. In order to suppress
high temperature IR signature from the nozzle surface, this study constructs a ceramic insulator between the
outermost surface layer and the innermost surface layer. The innermost surface layer is constituted by C-SiC
(carbon fiber reinforced silicon carbide composite) with excellent erosion performance for high speed and high
temperature gas above 1400 ◦ C, and the outermost layer is formed of CFRP (Carbon Fiber Reinforced Plastic) that
can maintain structural strength even with the axial thrust and inner pressure. In this study, the 2D-shape C-SiC
nozzle was fabricated through melting Si infiltration process, and the nozzle was completed by stacking ceramic
insulator and CFRP above it. The engine application test confirmed that the outermost temperature of the
proposed exhaust nozzle was kept below 100 ◦ C, and the IR signature was also reduced by 20% compared to the
coaxial exhaust nozzle. The 2D exhaust nozzle proposed in this study can be applied to aircraft that requires
stealth capability through structural optimization in the future works.
Introduction shows highest level of signature in the hot parts of the aircraft near 450
◦
C (723 K) [4,5]. The main sources of IR signatures are parts with high
Military aircraft are designed to have stealth capability by mini temperature such as exhaust nozzle, jet pipe, exhaust plume, rear fuse
mizing detectable signatures generated from engines and airframe to lage, and heated airframe skin. Because the IR detection system iden
enhance survivability during missions. The signatures are typically vi tifies the aircraft using IR signature discrepancy with surrounding
sual, aural, infrared (IR), and radio detection and ranging (RADAR) [1]. background, a technique is needed to suppress IR signature by lowering
Since 1960’s, in particular, as IR signature analysis techniques and the temperature of the hot parts of the aircraft.
detection systems are widely used in defense systems, many researches The turbofan engine, which is mainly used as a propulsion system for
on IR signature suppression have been conducted to improve stealth the aircraft, is driven by a jet gas, so the exhaust nozzle is heated by the
capability and survivability of aircraft [2]. plume and jet gas and the IR signature of 3 to 5um wavelength generated
The IR signature has the wavelength range of 0.7 to 1000 um, but from the rear and the bottom side. The researches on engine size
only the signature in the wavelength of 3 to 5 um and 8 to 12 um can be reduction, engine cycle tailoring, changes in nozzle exit area, masking of
detectable while the aircraft is maneuvered in the air due to absorption exhaust, using IR paints and plume/aerosol mixing have been studied to
and scattering by atmospheric CO2 and H2O [1,3]. According to Wien’s reduce IR signature, and the exhaust nozzle has been changed from a
displacement law, IR signature in the wavelength range of 3 to 5 um coaxial nozzle to a non-axisymmetric nozzle to reduce the rear IR
* Corresponding author.
E-mail address: yongha_kim@add.re.kr (Y. Kim).
https://doi.org/10.1016/j.rinp.2020.103395
Received 6 July 2020; Received in revised form 26 August 2020; Accepted 7 September 2020
Available online 13 September 2020
2211-3797/© 2020 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
S.J. Kim et al. Results in Physics 19 (2020) 103395
where, Ainlet and Aoutlet represent the inlet and outlet cross-sectional area
of the 2D exhaust nozzle, L represents total longitudinal length of the
nozzle, and x represents longitudinal position.
The cross-sectional area of the 2D exhaust nozzle has an ellipse
shape. Ratio (eellipse ) of major radius (rmajor ) of the ellipse with respect to
√̅̅̅̅̅̅̅̅̅̅̅̅̅
the equivalent radius (req = A2D /π) of nozzle cross-section were
designed as following equations to satisfy the area distribution of Fig. 2.
(x )
eellipse = k1 cos π + k2 (2)
L
2
S.J. Kim et al. Results in Physics 19 (2020) 103395
Fg is the gross thrust in each analysis, Fg,unmix is the sum of the thrust Fig. 5. Structural Layout of the 2D exhaust nozzle with multiple compos
that occurs in each flow when the core and bypass flows are not mixed, ite layers.
3
S.J. Kim et al. Results in Physics 19 (2020) 103395
thrust, and mixing efficiency based on Eq. (5) for the coaxial and 2D
exhaust nozzles (normalized by the results of the coaxial exhaust nozzle
without a lobed mixer). The results with and without the lobed mixer
were also compared.
In case of without the lobed mixer, mixing efficiency of the 2D
exhaust nozzle is not greater than the case of the coaxial exhaust nozzle.
However, by using the lobed mixer, mixing of core flow and bypass flow
is enhanced, and the 2D exhaust nozzle shows 1.5 times higher mixing
efficiency than the coaxial exhaust nozzle with the lobed mixer, and 5.5
times higher mixing efficiency than the case of absence of the lobed
mixer. Thus, we found that the lobed mixer is necessarily used together
to enhance mixing efficiency and decrease gas temperature of the 2D
exhaust nozzle. However, its values of mass flow rate and gross thrust
are degraded (3.0% and 4.7%, respectively) due to heterogeneity of gas
flow. Because the mass flow rate and gross thrust decrease, the operating
point of the engine should be set in consideration of the required engine
performance in the aircraft.
4
S.J. Kim et al. Results in Physics 19 (2020) 103395
1400 ◦ C, thus it is used for high temperature nozzle flaps, combustor can be typically fabricated by the method of CVI (Chemical Vapor
liner, turbine disk, and etc. And C-SiC is widely used for the engine Infiltration), LSI (Liquid Silicon Infiltration), and PIP (Polymer Infiltra
nozzle due to its remarkable erosion resistance. tion and Pyrolysis). CVI process can obtain high purity and high crys
Since CFRP is likely to lose strength at high temperature, the ceramic tallinity by the reaction gas deposition manufacturing process, but there
insulator layer should be designed to maintain surface temperature of are limitations such as residual void, very slow process, and requirement
the CFRP layer below 180 ◦ C. IR suppression is also possible because it of precise control equipment. In the case of PIP process, even if complex
can be maintained below the minimum temperature which can cause
3~5um IR signature. In this study, the C-SiC layer, the ceramic insulator
layer, and the CFRP layer were designed 5 mm, 20 mm, and 5 mm,
respectively. Detailed structural analysis and design will be covered
later through the related paper. This paper omits the detailed design to
focus on the concept of the 2D exhaust nozzle with multiple composite
layers and its effectiveness.
By calculating the visible area of the engine hot section viewed from
the rear, the area of 2D exhaust nozzle is reduced by 37% compared to
that of the coaxial nozzle, and it reduces IR signature that occurs in the
engine’s hot parts as shown in Fig. 6.
C-SiC layer
Fig. 10. Thermocouple positions on the 2D exhaust nozzle during the en
The C-SiC composite constituting the innermost layer of the nozzle gine test.
5
S.J. Kim et al. Results in Physics 19 (2020) 103395
shape can be produced at low cost by polymer pyrolysis method, but it is not needed. The C-SiC composite nozzle after Si infiltration is polished to
not suitable for the nozzle fabrication of this study due to void, low ensure a smooth flow path surface. Since the 2D exhaust nozzle is flat
crystallinity, and volume shrinkage problems. In this study, the LSI and has cavity inside, it is difficult to mold the whole part in one part.
process for infiltration of powder and melting Si is used to have the Thus, upper and lower parts of the C-SiC layer nozzle are individually
advantages of crystallinity, full mechanical strength over 1400 ◦ C, and fabricated, and then these parts are assembled into the one part by using
simple fabrication process [16–18]. The innermost layer consisted of C- ceramic bonding.
SiC was fabricated through the steps as shown in Fig. 7. However, in case of initial product, Si deficiency occurred at the rear
First, phenolic resin (R/C: 40~50%) is applied to #3327 carbon and Si was excessive at the front as Si flowed down by gravity due to Si
fabric arranged in the 0◦ direction and 90◦ direction, and then manu infiltration using the vertical chamber. To solve this problem, boron
factured in preform using the autoclave. Afterward, two stepwise car nitride dam were placed at regular intervals along the longitudinal di
bonizations are proceeded to prevent heat shock. Next, after Si is spread rection, and Si could be evenly infiltrated on the nozzle surface with
on the nozzle surface, the nozzle is inserted into a mold made of graphite minimization of Si flowed down (Fig. 8).
and Si infiltration is performed in a high temperature chamber. In this
step, Si infiltration is prevented by boron coating on the part where Si is
6
S.J. Kim et al. Results in Physics 19 (2020) 103395
the amount of heat transfer from the exhaust gases to the nozzle. The
phenomenon that the nozzle temperature decreases at the maximum
PLA point can be also explained by this cooling amount caused by the
convection (1100 s~1150 s, 1280 s~1350 s). High exhaust gas speed at
high PLA enhances air mixing on the nozzle surface and convection
cooling effect, as well. Of the four nozzle surface temperature mea
surement points, the highest temperature results can be seen at position
1 and 2 attached to the nozzle tip. This is because the nozzle tip is
located close to the hot exhaust gas and the part of the outermost CFRP
layer is directly exposed to the exhaust gas. In the case of the 2D exhaust
nozzle, the nozzle surface temperature was maintained below 100 ◦ C
during the entire engine test. According to the Wien’s displacement law
(λ = 2893
T μm), the IR signature in this temperature range is 7.7 um
wavelength band, and it is difficult to be detected due to atmospheric
scattering in the air.
The engine performance according to the nozzle type was compared
based on the engine thrust and specific fuel consumption. Fig. 12 is the
engine thrust value for the turbine inlet temperature, and it represents the
amount of energy converted to thrust from the combustion energy by the
nozzle. There is no difference in thrust between the two nozzle types up to
a certain turbine inlet temperature, but at the maximum thrust operating
Fig. 12. Comparisons of the engine thrust performance.
point, the thrust of 2D exhaust nozzle is about 2.5% lower than the one of
the coaxial exhaust nozzle. In case of SFC (specific fuel consumption),
Ceramic insulator layer and CFRP layer
which means fuel consumption versus thrust, the 2D exhaust nozzle is
about 3.0% larger than the coaxial exhaust nozzle as shown in Fig. 13. The
The insulator located on the C-SiC layer was made of block-shaped
thrust and the SFC performance deterioration are due to pressure loss on
pieces of ceramic insulator and bonded onto the C-SiC layer. Carbon/
the rough inner-surface of the 2D exhaust nozzle which is made of com
Epoxy prepreg was covered on it, and bagging and curing in the auto
posite material. However, the thrust and SFC deterioration of the 2D
clave were performed. The final geometry and dimensions of the nozzle
exhaust nozzle found in the engine test is not a serious level, so the gain
are adjusted through additional machining. In order to fasten the front
from reducing the nozzle surface temperature is greater.
end of the 2D exhaust nozzle and the duct #2 (Fig. 1), the flange part of
the nozzle which does not pass the hot exhaust gas was manufactured by
IR signature test
using SUS304. Since the ceramic insulator cannot be covered on the
whole C-SiC plane, the ceramic insulator is constructed from the front of
An engine with a 2D exhaust nozzle was applied to the aircraft to
the heating zone which is contacted with the high temperature/high
experimentally verify the IR reduction effect in the rear side of the
speed exhaust gas. Fig. 9 shows finally manufactured 2D exhaust nozzle
aircraft. The IR wavelength signal was measured using the MR304
with multiple composite layers.
model of ABB’s IR spectro-radiometer. The measuring position is 45
degrees to the rear of the aircraft, and it can measure the IR signature
Application test
from the exhaust nozzle and from the plume injected from the rear of the
aircraft. The aircraft was stationary on the ground and IR signature were
Engine test
measured for the engine start, flight idle, 50% PLA and 100% PLA
conditions.
Engine test was performed using the coaxial exhaust nozzle and the
The measured data from IR spectro-radiometer was analyzed to
2D exhaust nozzle under the same test conditions with the same turbo
quantitatively assess IR signature reduction performance of the 2D
engine, and engine performances and the surface temperature of the 2D
exhaust nozzle was measured. During the engine test, turbine inlet
temperature, engine rotor RPM, engine thrust, fuel consumption, and
nozzle surface temperatures were measured. K-type thermocouples,
measuring up to 1250 ◦ C, were attached to a total of four points on the
nozzle surface as shown in Fig. 10. Two points on the upper and bottom
surfaces of the nozzle part where the hot core gas directly hits (numbers
3 and 4 in Fig. 10), and two points of the nozzle tip were measured
(numbers 1 and 2 in Fig. 10).
Engine test sequences include starting condition, maximum thrust
condition, and slam up/down conditions. Temperatures on the 2D
exhaust nozzle surface with respect to PLA (Power lever angle) repre
senting engine thrust demand level, and turbine inlet temperature are
shown in Fig. 11.
Turbine inlet temperature increases to the same trend as PLA due to
increase of the combustion temperature, but the nozzle surface tem
perature tends to be different. In the early stage of engine start-up, the
nozzle surface temperature gradually increases due to the warming up of
the nozzle. However, the nozzle surface temperature increases even
though the PLA and turbine inlet temperature decreases (960 s~1000 s,
1150 s~1180 s), due to the reduced cooling effect caused by the con
vection of the ambient air on the outside of the nozzle as compared to Fig. 13. Comparisons of the engine SFC performance.
7
S.J. Kim et al. Results in Physics 19 (2020) 103395
Fig. 14. IR spectral irradiance measurement results (Left: Coaxial exhaust nozzle, Right: 2D exhaust nozzle).
exhaust nozzle. The MR304 IR spectro-radiometer can measure IR the nozzle maintained below 100 ◦ C can be easily scattered by the air,
signature in the 2~15um wavelength range, but in order to validate the thus it can reduce the probability of detection behind the aircraft. In the
IR signature reduction effect due to temperature reduction, the 2~6um IR signature measurement test by applying the nozzle to the aircraft, it
wavelength range IR signature was analyzed. Fig. 14 shows the spectral was verified that the 2D exhaust nozzle can reduce the IR signature by
irradiance results of the IR signature measured at 45 degrees behind the 20% than the coaxial exhaust nozzle made of steel.
aircraft under 100% PLA engine operating condition. Regardless of type The C-SiC constituting the innermost layer of the 2D exhaust nozzle
of the nozzle, the IR signature of near 4 um wavelength band is the has excellent high temperature abrasion resistance, but when manu
highest due to the plume. However, we can see that the overall IR factured by melting Si infiltration method, the Si may not be evenly
signature amplitude of the 2D exhaust nozzle is lower than that of the applied to the nozzle and thus may not secure high temperature abrasion
coaxial exhaust nozzle. Fig. 15 shows the quantitative value of the IR resistance. In this study, we use boron nitride to create partitions on the
signature level at each engine operating condition. It can be seen that nozzles and use them to prevent Si flowing down and Si tilting. This
the 2D exhaust nozzle can reduce the IR signature by 30% at maximum method can be useful for the production of more complex C-SiC
thrust condition and 20% at flight idle condition. This reduction in IR composites.
signature level suppression behind the aircraft can increase the stealth By changing the thickness of C-SiC layer, insulator layer, ad CFRP
capability and survivability of the aircraft. layer constituting 2D exhaust nozzle, nozzle abrasion resistance, struc
tural strength and heat transfer to nozzle outermost surface can be
Conclusion controlled. In addition, the weight of the nozzle is determined by the
total layer thickness. Therefore, in the future study, the structural design
In this study, we proposed the 2D exhaust nozzle with multiple study to optimize the nozzle weight and the IR signature suppression
composite layers that can suppress IR signature on high temperature performance will be conducted.
exhaust nozzle surface and verified its performance by fabricating and
testing it. The proposed 2D exhaust nozzle, which has an insulator layer CRediT authorship contribution statement
in the middle layer of the nozzle, has been shown to maintain surface
temperature below 100 ◦ C without significant degradation in engine Sun Je Kim: Conceptualization, Data curation, Investigation,
performance in the engine application test. IR signature emitted from Writing - original draft. Yeong Ryeon Kim: Conceptualization, Super
vision, Writing - review & editing. Yongha Kim: Conceptualization,
Investigation, Writing - review & editing. Myung Ho Kim: Data cura
tion, Investigation. MyungSup Lee: Data curation, Investigation.
Acknowledgment
References
[1] Mahulikar SP, Sonawane HR, Rao GA. Infrared signature studies of aerospace
Fig. 15. IR irradiance magnitude comparisons. vehicles. Prog Aerosp Sci 2007;43:218–45.
8
S.J. Kim et al. Results in Physics 19 (2020) 103395
[2] Liu J, Ji H. Investigation on infrared signature of axisymmetric vectoring exhaust [10] Capone FJ, Gowadia NS, Wooten WH. Performance characteristics of
system with infrared suppressions. J Thermophys Heat Transfer 2018;32(3): nonaxisymmetric nozzles installed on an F-18 propulsion model. J Aircraft 1980;17
627–36. (6):387–92.
[3] Burch DE, Gryvnak DA. Laboratory measurement of the infrared absorption by [11] Siefker RG, Vittal BR, Baker VD, Khalid SA, Loebig JC. Exhaust mixer and
H2O and CO2 in regions of weak absorption. In: Proc. SPIE 0142, Washington D.C., apparatus using same. US Patent, US 2004/0068981 A1, April, 2004.
USA; August 1978, p. 16–24. [12] Dawei L, Jun H, Zhiqiang S, Jinzu J. The effect of spoilers on jet mixing of lobed
[4] Mahulikar SP, Sane SK, Gaitonde UN, Marathe AG. Numerical studies of infrared nozzles. J Aerosp Technol Manag 2016;8(4):459–66.
signature levels of complete aircraft. Aeronautical J 2001;105(1046):185–92. [13] Bhasha GS, Malik P, Jain P. Ceramic composites for aerospace applications.
[5] Mahulikar SP, Rao GA, Kolhe PS. Infrared signature of low-flying aircraft and their Diffusion Foundations 2019;23:31–9.
rear fuselage skin’s emissivity optimization. J Aircraft 2006;43(1):226–32. [14] Shchegoleva NE, Evdokimov SA, Osin IV, Chainikova AS, Shavnev AA. High-
[6] Baranwal N, Mahulikar SP. IR signature study of aircraft engine for variation in temperature ceramic composites (SiC/SiCw). Glass Ceram 2020;77:47–50.
nozzle exit area. Infrared Phys Technol 2016;74:21–7. [15] Chawla KK. Composite Materials. Springer; 2019. p. 251–96.
[7] Gu BC, Baek SW, Jegal HW, Choi SM, Kim WC. Infrared signature characteristic of [16] Kumar S, Chandra R, Kumar A, Prasad NE, Manocha LM. C/SiC composites for
a microturbine engine exhaust plume. Infrared Phys Technol 2017;86:11–22. propulsion application. Compos Nanostruct 2015;7(4):225–30.
[8] Chopra KN. Analysis and modeling of IR signatures by optoelectronic techniques [17] Peterson PF, Forsberg C, Pickard PS. Advanced CSiC composites for high-
and countermeasures – a technical tutorial and review. Lat Am J Phys Educ 2018; temperature nuclear heat transport with helium, molten salts, and sulfur-iodine
12(3):1–10. thermochemical hydrogen process fluids. Nuclear Prod Hydrogen 2004:289–302.
[9] Banken GJ, Cornette WM, Gleason KM. Investigation of infrared characteristics of [18] Kim YC, Seo SK. Development of C/SiC composite parts for rocket propulsion.
three generic nozzle concepts. In: AIAA/SAE/ASME 16th Joint Propulsion J Korean Soc Propulsion Eng 2019;23(2):68–77.
Conference, Hartford, USA; June 1980, p. 1–11.