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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10

Occupant-Centric Demand Response for Thermostatically-Controlled Home Loads

Efficiently managing energy usage to balance supply and demand on the electric grid is crucial, especially with the widespread deployment of distributed variable renewable electricity generation. This paper introduces two duty-cycle control methods for heating systems, adjusting thermostat setpoints to limit and shift electricity demand. The control approaches employ innovative techniques, such as adaptive duty cycling, to prioritize household thermal comfort while reducing peak demand. These control methods can respond to signals from the electric grid, including demand targets and time-of-use tariffs, and were tested physically on an electric furnace and heat pump in a test home during winter conditions in 2021 and 2022. The results are given as average demand reductions and energy use impacts with respect to the average indoor-outdoor temperature difference during the control period. For heat pumps, demand limiting control reduced power by 18.5% and 23.3% for indoor-outdoor temperature differences of 30°F and 40°F. Preheating-based demand shifting achieved reductions of 34.8% and 33.2% for the same temperature differences. Electric furnace tests showed demand reductions of 33.8% and 25.3% for demand limiting, and 56.1% and 45.7% for preheating-based demand shifting. These findings highlight the potential for innovative control methods to enhance grid efficiency and reduce energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Residual stresses in Cu matrix composite surface deposits after laser melt injection

Abstract Tungsten carbide particles reinforced metal matrix composite (MMC) coatings can significantly improve surface wear resistance owing to their increased surface hardness. However, the presence of macro‐ and micro‐residual stresses in MMC coatings can have detrimental effects, such as reducing service life. In this study, neutron diffraction was used to determine the residual stresses in spherical fused tungsten carbide (sFTC) reinforced Cu matrix composite surface deposits after laser melt injection. We also developed a thermo‐mechanical coupled finite element model to predict residual stresses. Our findings reveal that sFTC/Cu composite deposits produced with a preheating temperature of 400°C have low residual stresses, with a maximum tensile residual stress of 98 MPa in the Cu matrix on the top surface. In contrast, the sFTC/bronze (CuAl10Ni5Fe4) composite deposit exhibits very high residual stresses, with a maximum tensile residual stress in the Cu matrix on the top surface reaching 651 MPa. These results provide a better understanding of the magnitudes and distributions of residual stresses in sFTC‐reinforced Cu matrix composite surface deposits manufactured via laser melt injection.

Zhang, Xingxing↗

High-speed phase contrast imaging of spray breakup of jet fuels under combusting conditions

X-ray phase contrast imaging is conducted at 90,517 Hz on a fuel spray to characterize the breakup of the bulk fuel into ligaments and individual droplets in a single-sector, swirl-stabilized combustor under reacting conditions. Phase contrast imaging is used to qualitatively assess spray breakup for two fuels: Jet-A, which represents a normal viscosity fuel, and a blend of JP-5 (64%) and farnesane (36% by volume), which represents a high-viscosity fuel, at three fuel-flow rates and two air inlet temperatures. Time-series images of the fuels show that atomization occurs much more rapidly at higher fuel pressure with thinner ligaments being rapidly shredded. The high-viscosity fuel is qualitatively observed to have markedly longer, thicker ligaments and larger droplet diameters after the primary breakup than the normal viscosity fuel. Using an image processing and droplet quantification strategy, the mean droplet velocity magnitudes were found to decrease with decreasing fuel pressure and fuel-flow rate. The increase in preheat temperature from 323 to 370 K results in an increase in the mean droplet velocity magnitude and a decrease in numerical average and Sauter mean diameter, indicating improved atomization. The high-viscosity fuel was found to have larger average droplet diameters at each condition than the normal viscosity fuel. The increased preheat is found to enhance the combustion efficiency, which is hypothesized to couple with the improved atomization due to the higher combustion temperatures. This indicates the importance of examining spray atomization and breakup under realistic combusting conditions for relevant fuels as the heat release directly couples with the atomization process.

42 ENGINEERING↗

Hot Electron Scaling and Energy Coupling In Nonlinear Laser Plasma Interactions

Energy conversion from high power lasers to energetic hot electrons is a fundamental phenomenon in laser-plasma interactions. At laser intensities above a few times 10 14 W/cm 2 , nonlinear laser-plasma interactions lead to the generation of hot electrons with a broad energy distribution at typical temperatures of 10’s – 100’s kilo-electron-volt (keV). The fraction of laser energy transferred to hot electrons, their energy distribution and energy coupling efficiency to the targets are strongly affected by the laser intensity, wavelength and the plasma condition. Most investigations to date that are related to the fusion of high-energy-density laboratory plasmas (HEDLP) are carried out with relatively moderate laser intensity and lower laser wavelength to minimize hot electron generation, as electron preheating can degrade the fuel assembly. An alternative fusion scheme known as shock ignition (SI) has been proposed, requiring a high intensity spike pulse at the end of a fuel assembly phase to generate a strong shock to ignite the fuel. An initial shock pressure of 0.3 Gbar is required for ignition-scale targets using the SI scheme, requiring a relatively high on-target laser intensity of 5-10X10 15 W/cm 2 for the spike pulse. At such intensities, copious hot electrons can be produced by laser-plasma-instabilities (LPI), e.g., Stimulated Raman Scattering (SRS) and Two-Plasmon Decay (TPD). While very energetic electrons (>200 keV) could preheat the fuel, electrons with moderate energies may actually be beneficial for the SI scheme. Electrons in the 50-100 keV range can be stopped in the compressed high-density outer ablator layer leading to an increase in the ignitor shock strength and therefore enhancing overall efficiency in the SI scheme. Considering this importance of total energy and temperature of hot electrons, it is necessary to understand the LPI in the SI high intensity regime. Characterizing the hot electron source and energy coupling is key to investigating the viability of the SI concept. The overall goal of the HEDLP award was to perform a detailed study of the scaling of hot electron generation and energy coupling on high power laser systems, with intensity, wavelength, and target ablator material relevant to the nonlinear laser-plasma interaction at SI relevant conditions. This was a collaborative project between the Center for Energy Research at the University of California, San Diego (UCSD) and General Atomics. The experiment was performed at the Omega Laser Facility at the Laboratory for Laser Energetics (LLE) in the University of Rochester. Specific objectives of the work were to: understand the basic physics of laser-plasma interactions and instabilities at high laser intensities (up to 10 17 W/cm 2 ) and the effects of low-Z ablator materials and laser wavelengths (IR pulse at 1.054 µm versus UV pulse at 0.351 µm) and intensity scaling, fully characterize the resultant hot electron energy distribution, validate hot electron energy deposition via collisional and kinetic processes in the target and the induced shocks in support of electron-assisted SI concept.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Influence of Process Parameters and Alloy Composition on Crack Mitigation in Selective Laser Melting

Microcracking and residual stresses are key limitations of laser powder bed fusion (LPBF), an additive manufacturing (AM) technique that uses a high power laser to consolidate successive layers of metal powder. For tungsten, these microcracks find their origin in the combination of a ductile-to-brittle transition (DBT) between 200°C and 400°C and high residual stresses. This work utilized in situ high speed video to capture the cracking mechanisms, and combined the experimental results with thermomechanical modeling to unveil correlations between crack network morphology and process parameter-related variables, such as the local temperature and residual stress distributions. Consequently, preheating and alloying with rare earth oxides were adopted as possible crack mitigation strategies, the efficacy of which was tested against the initial fundamental baseline results. Preheating temperatures above 500°C eliminated all cracking, though this threshold is expected to be higher when tungsten powder (higher oxygen content) is introduced. Alloying can serve as an active oxygen getter in the system, but the rare earth oxides in this work were too large to have significant contributions to crack-mitigation.

36 MATERIALS SCIENCE↗

Assess and Benchmark Magneto-Inertial Fusion (MIF) Scaling. Final Technical Report for the SNL/Rochester ALPHA Follow-on Project

This project was a follow-on to the Sandia National Laboratories (SNL) and the Laboratory for Laser Energetics (LLE) ARPA-E ALPHA project entitled “Demonstrating Fuel Magnetization and Laser Heating Tools for Low-Cost Fusion Energy”. The primary purpose of this follow-on project was to obtain additional data at the OMEGA facility to help better understand how MagLIF, a platform that has already demonstrated the scientific viability of magneto-inertial fusion, scales across a factor of 1000 in driver energy. A secondary aspect of this project was to extend simulations and analysis at SNL to cover a wider magneto-inertial fusion (MIF) parameter space and test scaling of those models across this wide range of input energies and conditions of the target. This work was successful in improving understanding of how key physics elements of MIF scales and improves confidence in setting requirements for fusion gain with larger drivers. The OMEGA experiments at the smaller scale verified the hypothesis that preheating the fuel plays a significant role in introducing wall contaminants that mix into the fuel and significantly degrade fusion performance. This contamination not only impacts target performance but the optimal input conditions for the target. However, analysis at the Z-scale showed that target performance at high preheat levels is limited by the Nernst effect, which advects magnetic flux from the hot spot, reducing magnetic insulation and consequently reduces the temperature of the fuel. The combination of MagLIF experiments at the disparate scales of OMEGA and Z along with a multiscale 3D simulation analysis has led to new insight into the physical mechanisms responsible for limiting target performance and provides important benchmarks to assess target scaling more generally for MIF schemes. Finally, in addition to the MagLIF related work, a semi-analytic model of liner driven Field Reversed Configuration (FRC) was developed that predicts the fusion gain for such systems. This model was also validated with 2D radiation magneto-hydrodynamic simulations and predicts that fusion gains of near unity could be driven by the Z machine.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Impact of Plate Thickness and Joint Geometry on Residual Stresses in 347H Stainless Steel Welds

Weldments of 347H stainless steel are potentially susceptible to stress relaxation cracking at elevated service temperatures. Mitigation of stress relaxation cracking susceptibility within a multipass weld requires a good understanding of welding practices and manufacturing techniques to control high tensile residual stresses. Here in this work, the dependence of residual stress distribution in 347H stainless steel on base plate thickness, joint geometry design, and preheating condition was systematically investigated by using three-dimensional finite element models. The finite element models were validated through good agreement between neutron diffraction measurements and calculated elastic strains. The single-V-groove welds with and without a preheating step all produced similar peak von Mises residual stresses, above 450 MPa, within both the fusion zone and heat-affected zone (HAZ). In plates thicker than 0.5 in. (12.7 mm), high tensile residual stress could be observed in a relatively large area, from the middle of the plate thickness to underneath the top surface. A double-V groove shifted the high tensile stress area to the middle thickness of the weld. A single-J-groove weld was able to confine the residual stress to a very small region near the middle thickness within the fusion zone and suppressed the von Mises residual stress within the HAZ to below 400 MPa.

14 SOLAR ENERGY↗

Distributed Temperature Monitoring of Tundish Refractory Lining Using Optical Fiber Sensors

Distributed temperature monitoring can provide useful insights into the thermal conditions in the continuous caster tundish that can affect operating stability and cast quality, such as preheat conditions, superheat uniformity, fill height, and refractory wear. In the current study, fiber optic sensors were embedded into the refractory lining of a lab-scale tundish to record the temperature profiles during dry-out, preheating, and direct molten steel exposure to demonstrate sensor performance. Additional trials were performed with fiber optic sensors embedded in an industrial tundish used in production. Furthermore, the results demonstrate that fiber optic sensors using Rayleigh technology can provide accurate distributed temperature measurements in refractory lined vessels and provide useful information about the process.

Continuous Caster↗

Energy and Environmental Analyses of a Solar–Gas Turbine Combined Cycle with Inlet Air Cooling

Sensitivity to ambient air temperatures, consuming a large amount of fuel, and wasting a significant amount of heat dumped into the ambient atmosphere are three major challenges facing gas turbine power plants. This study was conducted to simultaneously solve all three aforementioned GT problems using solar energy and introducing a new configuration that consists of solar preheating and inlet-air-cooling systems. In this study, air was preheated at a combustion chamber inlet using parabolic trough collectors. Then, inlet air to the compressor was cooled by these collectors by operating an absorption cooling cycle. At the design point conditions, this novel proposed integration resulted in a 6.87% relative increase in generated power and a 10.53% relative decrement in fuel consumption, achieving a 19.45% relative increment in the plant’s thermal efficiency. This was accompanied by a reduction of 0.026 kg/s, 4.2 kg/s, and 0.278 kg/s in CO 2 , CO, and NOx emissions, respectively. Finally, spider diagrams were employed to assess the impact of the operating parameters on the overall system’s performance and its associated environmental implications.

14 SOLAR ENERGY↗

Self-cycling fluid heater

A self-cycling fluid heater is described which includes a high temperature upstream preheater for elevating the stream temperature. A high intensity jet arc heater heats the preheated fluid stream to ultrahigh reaction temperatures and discharges the stream into an electric resistance tubular heat exchanger. The heat exchanger has variations in wall thickness at measured intervals along its length to control the temperature of the fluid passing through the heat exchanger for desired time intervals to provide the specified chemical reactions desired.

Moen, W. K.↗

Techniques for aerothermal tests of large, flightweight thermal protection panels in a Mach 7 wind tunnel

Recently developed experimental techniques permit evaluating thermal performance and structural integrity of full-scale panel concepts applicable to reentry and hypersonic vehicles in the Langley 8-foot high-performance structures tunnel. Rate and magnitude of surface heating and differential-pressure loading are independently controlled. Realistic temperature distributions are radiantly preheated into the panel prior to aerodynamic heating, and stream conditions are preselected to sustain the preheat surface heating input during aerodynamic exposure. During tunnel start and shutdown, panels are shielded outside the stream from potentially damaging transient acoustics and buffeting and are then rapidly inserted into the hypersonic flow. Infrared radiometry provides detailed surveys of surface temperatures.

Deveikis, W. D.↗

Hydrogen rich gas generator

A process and apparatus is described for producing a hydrogen rich gas by introducing a liquid hydrocarbon fuel in the form of a spray into a partial oxidation region and mixing with a mixture of steam and air that is preheated by indirect heat exchange with the formed hydrogen rich gas, igniting the hydrocarbon fuel spray mixed with the preheated mixture of steam and air within the partial oxidation region to form a hydrogen rich gas.

Houseman, J.↗

Rock failure analysis by combined thermal weakening and water jet impact

The influence of preheating on the initiation of fracture in rocks subjected to the impingement of a continuous water jet is studied. Preheating the rock is assumed to degrade its mechanical properties and strength in accordance with existing experimental data. The water jet is assumed to place a quasi-static loading on the surface of the rock. The loading is approximated by elementary functions which permit analytic computation of the induced stresses in a rock half-space. The resulting stresses are subsequently coupled with the Griffith criteria for tensile failure to estimate the change, due to heating, in the critical stagnation pressure and velocity of the water jet required to cause failure in the rock.

Nayfeh, A. H.↗

Effect of degree of fuel vaporization on emissions for a premixed-prevaporized combustor system

The impact of the degree of fuel vaporization upon emission from a flametube combustor was studied using an inlet air pressure of 3 x 10 to the 5th power pascals, inlet air temperatures of 600K and 700K, a reference velocity of 35 meters per second and equivalence ratios of .6 and .72 using Jet A fuel. Incoming air was preheated to temperatures from 600K to 700K by a nonvitiating preheater. Jet A fuel was injected into this airstream through two different fuel injectors manifolded together and mounted in series upstream of a watercooled preforated plate flameholder. The fuel-air mixture burned in a watercooled combustor section. Samples of the fuel-air mixture upstream of the flameholder were obtained for analysis to determine the local degree of fuel vaporization and the fuel-air ratio. Samples of the combustion products were analyzed to determine gaseous emissions. The effects of vaporization on carbon monoxide and nitric on carbon monoxide and nitric oxide emissions are presented.

Cooper, L. P.↗

MHD performance calculations with oxygen enrichment

The impact of oxygen enrichment of the combustion air on the generator and overall plant performance was studied for the ECAS-scale MHD/steam plants. A channel optimization technique is described and the results of generator performance calculations using this technique are presented. Performance maps were generated to assess the impact of various generator parameters. Directly and separately preheated plant performance with varying O2 enrichment was calculated. The optimal level of enrichment was a function of plant type and preheat temperature. The sensitivity of overall plant performance to critical channel assumptions and oxygen plant performance characteristics was also examined.

Pian, C. C. P.↗

Ceramic applications in the advanced Stirling automotive engine

The requirements of the ideal Stirling cycle, as well as basic types of practical engines are described. Advantages, disadvantages, and problem areas of these Stirling engines are discussed. The potential for ceramic components is also considered. Currently ceramics are used in only two areas, the air preheater and insulating tiles between the burner and the heater head. For the advanced Stirling engine to achieve high efficiency and low cost, the principal components are expected to be made from ceramic materials, including the heater head, air preheater, regenerator, the burner and the power piston. Supporting research and technology programs for ceramic component development are briefly described.

Tomazic, W. A.↗

Single-family-residence solar heating--Carlsbad, New Mexico

Solar-heating and hot-water system includes 408 square feet of flat-plate air collectors, rock storage bin, energy transport system, air-to-water heat exchanger, controls, and hot-water preheat tank. Hot-air oil furnace supplies auxiliary space heating, and electricity powers air-handler blower and hot water preheat pump. For 12 month period, system provided 43 percent of space-heating and 53 percent of hot-water energy; net energy savings were 23.072 million Btu.

Source record↗

Solar energy system performance evaluation report for Solaron-Duffield, Duffield, Virginia

The Solaron Duffield Solar Energy System was designed to provide 51 percent of the space heating, and 49 percent of the domestic hot water (DHW) to a two story 1940 square foot area residence using air as the transport medium. The system consists of a 429 square foot collector array, a 265 cubic foot rock thermal storage bin, heat exchangers, an 80 gallon DHW preheat tank, pumps, blowers, controls, air ducting and associated plumbing. A air-to-liquid heat pump coupled with a 1,000gallon water storage tank provides for auxiliary space heating and can also be used for space cooling. A 52 gallon electric DHW tank using the solar preheated water provides domestic hot water to the residence. The solar system, which became operational July 1979, has the following modes of operation: First Stage: (1) collector to storage and DHW; (2)collector to space heating; (3) storage to load. Second Stage: (4) heat pump auxiliary direct; (5) auxiliary heat from heat pump storage. Third Stage: (6) electrical resistance (strip) heat.

Source record↗