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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part I

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio, and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. A high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the first to two papers describing the development of a combustion system combining lean-stratified combustion with Miller cycle for downsized boosted applications. The work was completed under a multi-year US DOE project. The goal was to define a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to highloads. Some of the unique challenges in synergistically combining the two concepts are highlighted in this paper. Here, a central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute (lean plus EGR) mixtures when properly matched to fuel spray characteristics, a multiple-injection strategy, and a high-energy ignition system. Other challenges specific to meeting exhaust emissions requirements with a high-efficiency engine are also explored in this study. In this Part 1 of the paper, the single-cylinder combustion system design, analysis, and testing is described. Multicylinder engine system design, analysis and development is described in Part 2 of the paper.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Next-Cycle Optimal Dilute Combustion Control via Online Learning of Cycle-to-Cycle Variability Using Kernel Density Estimators

Dilute combustion using exhaust gas recirculation (EGR) presents a cost-effective method for increasing the efficiency of spark-ignition (SI) engines. However, the maximum amount of EGR that can be used at a given condition is limited by a rapid increment of cycle-to-cycle variability (CCV). This study describes a methodology to design a model-based stochastic optimal controller to adjust the cycle-to-cycle fuel injection quantity in order to reduce CCV and further extend the dilute limit. Given the complexity and chaotic nature of combustion events, the controller was enhanced with online learning in order to identify the statistical properties of combustion efficiency, which are needed to generate predictions for next-cycle events. This study showed that a kernel density estimator (KDE) can be used to learn the combustion properties in real time and can be incorporated into the feedback policy in order to calculate the optimal control command. Experimental results suggested that the dilute limit can be extended from 18.5% to 21% EGR fraction at an operating condition relevant for highway cruising. Additionally, the proposed controller can achieve a large CCV reduction with less fuel enrichment compared to previous methods, overall contributing to an increase in 0.2% indicated fuel conversion efficiency.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1933

Fuel Vaporization and Its Effect on Combustion in a High-Speed Compression-Ignition Engine

The tests discussed in this report were conducted to determine whether or not there is appreciable vaporization of the fuel injected into a high-speed compression-ignition engine during the time available for injection and combustion. The effects of injection advance angle and fuel boiling temperature were investigated. The results show that an appreciable amount of the fuel is vaporized during injection even though the temperature and pressure conditions in the engine are not sufficient to cause ignition either during or after injection, and that when the conditions are such as to cause ignition the vaporization process affects the combustion. The results are compared with those of several other investigators in the same field.

Rothrock, A M↗
DOE OSTI2021

UKy-CAER Heat Integrated Transformative CO 2 Capture Process in Pulverized Coal Power Plants

The goal of this Phase II Topical Report is to summarize the work for public domain conducted on project DE-FE0031583. Building upon the Design Basis completed during Phase I and in accordance with the Statement of Project Objectives (SOPO), the University of Kentucky (UK) Center for Applied Energy Research (CAER) (Recipient) along with team members has completed the Front End Engineering Design (FEED) for its advanced, versatile post-combustion CO 2 capture system (CCS) at the 10 MWe large pilot scale to be installed at the Wyoming (WY) Integrated Test Center (ITC), using a heat integrated process with split-rich fed, two-stage stripping and any advanced solvent to enhance the CO 2 absorber performance and lower the cost of CO 2 capture. The proposed project (Phases I-III) involves the design, fabrication, installation, testing and evaluation of a large pilot scale facility that will demonstrate the UK CAER transformative CCS integrated with an operating power plant. The work performed in Phase I, detailed in the Phase I Topical Report that was submitted in March 2019, included formation of a project team, securing the host site, and completing pre-FEED design basis, a cost estimation, a preliminary techno-economic analysis (TEA) and an environmental information volume (EIV). The work performed in Phase II, detailed in this Phase II Topical Report, includes completion of FEEDs, completion of a process risk analysis (PRA), obtaining necessary permits, updating the EIV and TEA, updating the cost and schedule estimate for the Phase III scope of work (SOW) and securing the necessary cost share. Updated information is provided on the current status of the UK CAER CCS technology and the project is ready to begin immediately detailed design, construction and operation of the proposed pilot.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Numerical modeling of hydrogen mixing in a direct-injection engine fueled with gaseous hydrogen

Hydrogen is considered as one of the most promising options to achieve effective decarbonization of the energy and transportation sectors. As such, it has recently been receiving increasing attention because of its promising potential as an energy carrier for advanced energy and propulsion systems. With a focus on internal combustion engines, direct injection (DI) of gaseous hydrogen during the compression stroke offers great potential for high engine efficiency and specific power while reducing the risk of backfiring and pre-ignition issues. Therefore, many experimental and numerical efforts have recently been dedicated to understanding the physical and chemical behaviors of hydrogen in engine during mixing and combustion. This study focuses on computational fluid dynamics (CFD) modeling of the hydrogen DI process in a hydrogen optical research engine. Under the conditions studied, gaseous hydrogen is injected into the combustion chamber via a centrally located single-hole injector at a pressure of 100 bar. Two configurations, namely low-and high-tumble, are investigated to understand the impact of different in-cylinder flow patterns on the fuel-air mixture preparation. Simulations are carried out using the commercial CFD software CONVERGE. Here, the in-cylinder turbulence is modeled with an unsteady Reynolds-averaged Navier-Stokes (URANS) formulation closed by the renormalization group (RNG) k-ε model. Several numerical methods and model constants, including but not limited to turbulent Schmidt number, are evaluated. The numerical results are systematically compared against experimental measurements of velocity and hydrogen concentration fields on the vertical center plane to assess the performance of the CFD model, unveil the physics of hydrogen mixing, and establish best practices for modeling hydrogen DI under relatively high injection pressure conditions.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2015

High Thermal Conductivity NARloy-Z-Diamond Composite Liner for Advanced Rocket Engines

NARloy-Z (Cu-3Ag-0.5Zr) alloy is state-of-the-art combustion chamber liner material used in liquid propulsion engines such as the RS-68 and RS-25. The performance of future liquid propulsion systems can be improved significantly by increasing the heat transfer through the combustion chamber liner. Prior work1 done at NASA Marshall Space Flight Center (MSFC) has shown that the thermal conductivity of NARloy-Z alloy can be improved significantly by embedding high thermal conductivity diamond particles in the alloy matrix to form NARloy-Z-diamond composite (fig. 1). NARloy-Z-diamond composite containing 40vol% diamond showed 69% higher thermal conductivity than NARloy-Z. It is 24% lighter than NARloy-Z and hence the density normalized thermal conductivity is 120% better. These attributes will improve the performance and life of the advanced rocket engines significantly. The research work consists of (a) developing design properties (thermal and mechanical) of NARloy-Z-D composite, (b) fabrication of net shape subscale combustion chamber liner, and (c) hot-fire testing of the liner to test performance. Initially, NARloy-Z-D composite slabs were made using the Field Assisted Sintering Technology (FAST) for the purpose of determining design properties. In the next step, a cylindrical shape was fabricated to demonstrate feasibility (fig. 3). The liner consists of six cylinders which are sintered separately and then stacked and diffusion bonded to make the liner (fig. 4). The liner will be heat treated, finish-machined, and assembled into a combustion chamber and hot-fire tested in the MSFC test facility (TF 115) to determine perform.

Bhat, Biliyar↗
DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part 2

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. Here, a high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the second of two papers describing the multi-cylinder integration of a technology package combining lean-stratified combustion with Miller cycle for downsized boosted applications. The first paper describes the design, analysis and single-cylinder testing conducted to down-select the combustion system deployed to the multi-cylinder engine. This paper defines a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to high-loads. A central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute mixtures when properly matched to fuel spray characteristics, injection strategy, and a high-energy ignition system. Boost system layout and base engine architecture were selected to minimize parasitics and maximize after treatment effectiveness. A multi-cylinder engine was developed and calibrated over a steady-state map. Results fed vehicle simulations over the EPA city and highway test cycles to predict the fuel economy improvement and tailpipe emissions potential. Fuel economy improvements over the baseline vehicle were projected at 42% and 39% for active-urea and passive-ammonia SCR after treatment systems respectively. Controls complexity to achieve regulatory compliance and the cost of the lean after treatment system were identified as the primary challenges to commercial viability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2009

Environmental Barrier Coatings for Turbine Engines: A Design and Performance Perspective

Ceramic thermal and environmental barrier coatings (TEBC) for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating long-term durability remains a major concern with the ever-increasing temperature, strength and stability requirements in engine high heat-flux combustion environments, especially for highly-loaded rotating turbine components. Advanced TEBC systems, including nano-composite based HfO2-aluminosilicate and rare earth silicate coatings are being developed and tested for higher temperature capable SiC/SiC ceramic matrix composite (CMC) turbine blade applications. This paper will emphasize coating composite and multilayer design approach and the resulting performance and durability in simulated engine high heat-flux, high stress and high pressure combustion environments. The advances in the environmental barrier coating development showed promise for future rotating CMC blade applications.

Zhu, Dongming↗
DOE OSTI2022

Additive manufacturing of ceramic materials for energy applications: Road map and opportunities

Among engineering materials, ceramics are indispensable in energy applications such as batteries, capacitors, solar cells, smart glass, fuel cells and electrolyzers, nuclear power plants, thermoelectrics, thermoionics, carbon capture and storage, control of harmful emission from combustion engines, piezoelectrics, turbines and heat exchangers, among others. Advances in additive manufacturing (AM) offer new opportunities to fabricate these devices in geometries unachievable previously and may provide higher efficiencies and performance, all at lower costs. This article reviews the state of the art in ceramic materials for various energy applications. The focus of the review is on material selections, processing, and opportunities for AM technologies in energy related ceramic materials manufacturing. The aim of the article is to provide a roadmap for stakeholders such as industry, academia and funding agencies on research and development in additive manufacturing of ceramic materials toward more efficient, cost-effective, and reliable energy systems.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Advanced High Pressure O2/H2 Technology

Activities in the development of advanced high pressure oxygen-hydrogen stage combustion rocket engines are reported. Particular emphasis is given to the Space Shuttle main engine. The areas of engine technology discussed include fracture and fatigue in engine components, manufacturing and producibility engineering, materials, bearing technology, structure dynamics, fluid dynamics, and instrumentation technology.

Morea, S. F.↗
NASA NTRS1992

Advanced nozzle and engine components test facility

A test facility for conducting scaled advanced nozzle and engine component research is described. The CE-22 test facility, located in the Engine Research Building of the NASA Lewis Research Center, contains many systems for the economical testing of advanced scale-model nozzles and engine components. The combustion air and altitude exhaust systems are described. Combustion air can be supplied to a model up to 40 psig for primary air flow, and 40, 125, and 450 psig for secondary air flow. Altitude exhaust can be simulated up to 48,000 ft, or the exhaust can be atmospheric. Descriptions of the multiaxis thrust stand, a color schlieren flow visualization system used for qualitative flow analysis, a labyrinth flow measurement system, a data acquisition system, and auxiliary systems are discussed. Model recommended design information and temperature and pressure instrumentation recommendations are included.

Beltran, Luis R.↗
NASA NTRS1992

Advanced nozzle and engine components test facility

A test facility for conducting scaled advanced nozzle and engine component research is described. The CE-22 test facility, located in the Engine Research Building of the NASA Lewis Research Center, contains many systems for the economical testing of advanced scale-model nozzles and engine components. The combustion air and altitude exhaust systems are described. Combustion air can be supplied to a model up to 40 psig for primary air flow, and 40, 125, and 450 psig for secondary air flow. Altitude exhaust can be simulated up to 48,000 ft, or the exhaust can be atmospheric. Descriptions of the multiaxis thrust stand, a color schlieren flow visualization system used for qualitative flow analysis, a labyrinth flow measurement system, a data acquisition system, and auxiliary systems are discussed. Model recommeded design information and temperature and pressure instrumentation recommendations are included.

Beltran, Luis R.↗
DOE OSTI2020

CONTROLLED END GAS AUTO IGNITION WITH EXHAUST GAS RECIRCULATION ON A STOICHIOMETRIC, SPARK IGNITED, NATURAL GAS ENGINE

The goal of this study is to address fundamental limitations to achieving diesel-like efficiencies in heavy duty on-highway natural gas (NG) engines. Engine knock and misfire are barriers to pathways leading to higher efficiency engines. This study explores enabling technologies for development of high efficiency stoichiometric, spark ignited, natural gas engines. These include design strategies for fast and stable combustion and higher dilution tolerance. Additionally, advanced control methodologies are implemented to maintain stable operation between knock and misfire limits. To implement controlled end- gas autoignition (C-EGAI) strategies a Combustion Intensity Metric (CIM) is used for ignition control with the use of a Woodward large engine control module (LECM). Tests were conducted using a single cylinder, variable compression ratio, cooperative fuel research (CFR) engine with baseline conditions of 900 RPM, engine load of 800 kPa indicated mean effective pressure (IMEP), and stoichiometric air/fuel ratio. Exhaust gas recirculation (EGR) tests were performed using a custom EGR system that simulates a high pressure EGR loop and can provide a range of EGR rates from 0 to 40%. The experimental measurements included the variance of EGR rate, compression ratio, engine speed, IMEP, and CIM. These five variables were optimized through a Modified Box- Benken design Surface Response Method (RSM), with brake efficiency as the merit function. A positive linear correlation between CIM and f-EGAI was identified. Consequently, CIM was used as the feedback control parameter for C-EGAI. As such, implementation of C-EGAI effectively allowed for the utilization of high EGR rates and CRs, controlling combustion between a narrower gap between knock and lean limits. The change from fixed to parametric ignition timing with CIM targeted select values of f-EGAI with an average coefficient of variance (COV) of peak pressure of 5.4. The RSM efficiency optimization concluded with operational conditions of 1080 RPM, 1150 kPa IMEP, 10.55:1 compression ratio, and 17.8% EGR rate with a brake efficiency of 21.3%. At this optimized point of peak performance, a f-EGAI for C-EGAI was observed at 34.1% heat release due to auto ignition, a knock onset crank angle value of 10.3° aTDC and ignition timing of - 24.7° aTDC. This work has demonstrated that combustion at a fixed f-EGAI can be maintained through advanced ignition control of CIM without experiencing heavy knocking events.

Cooperative Fuel Research Engine, Auto Ignition, E↗
NASA NTRS1932

Compression-ignition engine tests of several fuels

The tests reported in this paper were made to devise simple engine tests which would rate fuels as to their comparative value and their suitability for the operating conditions of the individual engine on which the tests are made. Three commercial fuels were used in two test engines having combustion chambers with and without effective air flow. Strictly comparative performance tests gave almost identical results for the three fuels. Analysis of indicator cards allowed a differentiation between fuels on a basis of rates of combustion. The same comparative ratings were obtained by determining the consistent operating range of injection advance angle for the three fuels. The difference in fuels is more pronounced in a quiescent combustion chamber than in one with high-velocity air flow. A fuel is considered suitable for the operating conditions of an engine with a quiescent combustion chamber if it permits the injection of the fuel to be advanced beyond the optimum without exceeding allowable knock or allowable maximum cylinder pressures.

Spanogle, J A↗
NASA NTRS2000

Active Combustion Control for Aircraft Gas Turbine Engines

Lean-burning combustors are susceptible to combustion instabilities. Additionally, due to non-uniformities in the fuel-air mixing and in the combustion process, there typically exist hot areas in the combustor exit plane. These hot areas limit the operating temperature at the turbine inlet and thus constrain performance and efficiency. Finally, it is necessary to optimize the fuel-air ratio and flame temperature throughout the combustor to minimize the production of pollutants. In recent years, there has been considerable activity addressing Active Combustion Control. NASA Glenn Research Center's Active Combustion Control Technology effort aims to demonstrate active control in a realistic environment relevant to aircraft engines. Analysis and experiments are tied to aircraft gas turbine combustors. Considerable progress has been shown in demonstrating technologies for Combustion Instability Control, Pattern Factor Control, and Emissions Minimizing Control. Future plans are to advance the maturity of active combustion control technology to eventual demonstration in an engine environment.

DeLaat, John C.↗
DOE OSTI2023

Examination of a Methane/Diesel RCCI Engine Using Pele: Preprint

Multi-fuel, advanced injection strategies have become increasingly promising as a strategy to mitigate the emissions generated from internal combustion engines. By carefully controlling the combustion phasing in-cylinder, these new multi-pulse, multi-fuel injection strategies are able to burn in the low-temperature combustion regime where both NOx and soot are not readily produced, reducing the need for extensive exhaust gas recirculation systems. In this study, we examine a reactivity-controlled compression ignition (RCCI) strategy that uses an early pre-filled methane-air mixture with low turbulence background as the low-reactivity fuel and a direct injection of four discrete dodecane jets as a surrogate for the high-reactivity diesel fuel. We use the Pele software suite, a highly optimized, exascale-ready, adaptive mesh refinement codebase to perform high-resolution numerical simulations of a scaled down, single cylinder from the RCCI engine. Here, we resolve the ignition kernels down to micrometer scales and present several statistical quantities evaluating the development of the flow and detailing the onset of ignition and subsequent flame development. Particular attention is paid to the conditions surrounding the onset of the first ignition kernels and discussing what led to the development of those conditions.

CFD↗
DOE OSTI2022

Evaluating Class 6 Delivery Truck Fuel Economy and Emissions Using Vehicle System Simulations for Conventional and Hybrid Powertrains and Co-Optima Fuel Blends

The US Department of Energy’s Co-Optimization of Engine and Fuels Initiative (Co-Optima) investigated how unique properties of bio-blendstocks considered within Co-Optima help address emissions challenges with mixing controlled compression ignition (i.e., conventional diesel combustion) and enable advanced compression ignition modes suitable for implementation in a diesel engine. Additionally, the potential synergies of these Co-Optima technologies in hybrid vehicle applications in the medium- and heavy-duty sector was also investigated. In this work, vehicles system were simulated using the Autonomie software tool for quantifying the benefits of Co-Optima engine technologies for medium-duty trucks. A Class 6 delivery truck with a 6.7 L diesel engine was used for simulations over representative real-world and certification drive cycles with four different powertrains to investigate fuel economy, criteria emissions, and performance. Comparisons were made between ultralow-sulfur diesel and a blend of 25% hexyl hexanoate with diesel. Model validation data were informed by 2019 model year Cummins ISB 6.7 L diesel engine maps and transient validation data in a pre-production hybrid configuration and a direct dyno coupled configuration with diesel fuel and a blend of 25% hexyl hexanoate with diesel.

33 ADVANCED PROPULSION SYSTEMS↗