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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 217 records · Page 12

Analysis of Apex Seal Friction Power Loss in Rotary Engines

An analysis of the frictional losses from the apex seals in a rotary engine was developed. The modeling was initiated with a kinematic analysis of the rotary engine. Next a modern internal combustion engine analysis code was altered for use in a rotary engine to allow the calculation of the internal combustion pressure as a function of rotor rotation. Finally the forces from the spring, inertial, and combustion pressure on the seal were combined to provide the frictional horsepower assessment.

Handschuh, Robert F.↗

Large-scale inflatable structures for tunnel protection: a review of the Resilient Tunnel Plug project

The protection of underground civil infrastructure continues to be a high priority for transportation and transit security agencies. In particular, rail transit tunnels running under bodies of water are susceptible to disruptions due to flooding caused by extraordinary climatic events such as hurricanes or other events resulting from human activities. Several events have taken place in the past decades that have demonstrated the need to mitigate vulnerabilities or, at least, minimize the consequences of catastrophic events. Although it is impossible to prevent all situations that can lead to flooding, damage can be substantially decreased by reducing the area affected by the event. To minimize the effects of an event, a possible approach is to compartmentalize the tunnel system by creating temporary barriers that can contain the propagation of flooding until a more permanent solution can be implemented. One way to create a temporary barrier is by the deployment of a large-scale inflatable structure, also known as an inflatable plug. In such an application, the inflatable structure is prepared for placement, either permanently or temporally, and maintained ready for deployment, inflation, and pressurization when needed. The internal plug pressure imparts a normal force against the tunnel wall surface with the friction between the plug and tunnel surfaces opposing axial movement of the plug. The sealing effectiveness depends on the ability of the inflatable structure to self-deploy and fit, without human intervention, to the intricacies of the perimeter of the conduit being sealed. Primary design constraints include having the plug stowed away from the dynamic envelope of the trains and being able to withhold the pressure of the flooding water. This work presents a compilation of the main aspects of the activities completed for the development of large-scale inflatable structures as part of the Resilient Tunnel Plug (RTP) Project. The main test results and lessons learned are presented to demonstrate the viability of implementing large-scale inflatable plugs for the containment of flooding in rail tunnels systems. Over 400 coupon and specimen tests, 200 reduced scale tests, and 100 full-scale tests were conducted to demonstrate the efficacy of the design of different prototypes over a 10-year research and development project. The culmination of the work was 12 large-scale flooding demonstrations where the inflatable tunnel plug was shown able to be deployed remotely and withstand a simulated flooding event.

42 ENGINEERING↗

Convection in Scaled Turbine Internal Cooling Passages With Additive Manufacturing Roughness

Abstract Additive manufacturing processes, such as direct metal laser sintering (DMLS), enable the creation of novel turbine cooling internal passages and systems. However, the DMLS method produces a significant and unique surface roughness. Previous work in scaled passages analyzed pressure losses and friction factors associated with the rough surfaces, as well as investigated the velocity profiles and turbulent flow characteristics within the passage. In this study, the heat transfer characteristics of scaled additively manufactured surfaces were measured using infrared (IR) thermography. Roughness panels were CNC machined from plates of aluminum 6061 to create near isothermal roughness elements when heated. Fluid resistance differences between the aluminum roughness panels and roughness panels constructed from ABS plastic using the same roughness patterns from McClain et al. (2020, “Flow in a Simulated Turbine Blade Cooling Channel With Spatially Varying Roughness Caused by Additive Manufacturing Orientation,” ASME Turbo Expo 2020, Turbomachinery Technical Conference and Exposition, Virtual Conference, Sept. 21–25, GT2020-16069) were investigated. Finally, the overall thermal performance enhancements and friction losses were assessed through the calculation of surface averaged “global thermal performance” ratios. The global thermal performance characterizations indicate results in-line with those found for traditional commercial roughness and slightly below traditional internal passage convection enhancement methods such as swirl chambers, dimples, and ribs. The passages investigated in this study do not include compressibility effects or the long-wavelength artifacts and channel geometric deviations observed by Wildgoose et al. (2020, “Impact of Additive Manufacturing on Internal Cooling Channels with Varying Diameters and Build Directions,” ASME Turbo Expo 2020, Turbomachinery Technical Conference and Exposition, Virtual Conference, Sept. 21–25, GT2020-15049). However, the results of this study indicate that, based on the roughness augmentation alone, artificial convective cooling enhancers such as turbulators or dimples may still be required for additively manufactured turbine component cooling.

Engineering↗

Methods for determining the internal thrust of scramjet engine modules from experimental data

Methods for calculating zero-fuel internal drag of scramjet engine modules from experimental measurements are presented. These methods include two control-volume approaches, and a pressure and skin-friction integration. The three calculation techniques are applied to experimental data taken during tests of a version of the NASA parametric scramjet. The methods agree to within seven percent of the mean value of zero-fuel internal drag even though several simplifying assumptions are made in the analysis. The mean zero-fuel internal drag coefficient for this particular engine is calculated to be 0.150. The zero-fuel internal drag coefficient when combined with the change in engine axial force with and without fuel defines the internal thrust of an engine.

Voland, Randall T.↗

Flow and arrest in stressed granular materials

Flowing granular materials often abruptly arrest if not driven by sufficient applied stresses. Such abrupt cessation of motion can be economically expensive in industrial materials handling and processing, and is significantly consequential in intermittent geophysical phenomena such as landslides and earthquakes. Using discrete element simulations, we calculate states of steady flow and arrest for granular materials under the conditions of constant applied pressure and shear stress, which are also most relevant in practice. Here the material can dilate or compact, and flow or arrest, in response to the applied stress. Our simulations highlight that under external stress, the intrinsic response of granular materials is characterized by uniquely-defined steady states of flow or arrest, which are highly sensitive to interparticle friction. While the flowing states can be equivalently characterized by volume fraction, coordination number or internal stress ratio, to characterize the states of shear arrest, one needs to also consider the structural anisotropy in the contact network. Here, we highlight the role of dilation in the flow-arrest transition, and discuss our findings in the context of rheological transitions in granular materials.

36 MATERIALS SCIENCE↗

Aircraft Engine Sump Fire Mitigation

An investigation was performed of the conditions in which fires can result and be controlled within the bearing sump simulating that of a gas turbine engine; Esso 4040 Turbo Oil, Mobil Jet 2, and Monsanto MCS-2931 lubricants were used. Control variables include the oil inlet temperature, bearing temperature, oil inlet and scavenge rates, hot air inlet temperature and flow rate, and internal sump baffling. In addition to attempting spontaneous combustion, an electric spark and a rub (friction) mechanism were employed to ignite fires. Spontaneous combustion was not obtained; however, fires were readily ignited with the electric spark while using each of the three test lubricants. Fires were also ignited using the rub mechanism with the only test lubricant evaluated, Esso 4040. Major parameters controlling ignitions were: Sump configuration; Bearing and oil temperatures, hot air temperature and flow and bearing speed. Rubbing between stationary parts and rotating parts (eg. labyrinth seal and mating rub strip) is a very potent fire source suggesting that observed accidental fires in gas turbine sumps may well arise from this cause.

Rosenlieb, J. W.↗

Tailoring Surface Roughness Using Additive Manufacturing to Improve Internal Cooling

Abstract Surface roughness present on internal cooling channels produced with additive manufacturing has been previously shown to augment heat transfer and pressure loss to levels similar to traditionally cast turbulators. Given the ability of the surface roughness to improve the cooling performance of small cooling channels, the question arises on whether there is an optimal combination of random roughness features to maximize internal cooling performance. To investigate this question, test coupons with different surface roughness morphologies and magnitudes were manufactured by manipulating the parameters in the laser powder bed fusion additive manufacturing process. The coupons were tested to characterize the friction factor and Nusselt number of the cooling channels over a range of Reynolds numbers. Results showed that certain roughness combinations outperformed others, increasing the internal cooling performance of the channels. Additionally, manipulation of the performance using the process parameters allowed for reductions in build time, which could be useful for controlling component cost.

Engineering↗

Sound Speed as a Candidate for Internal Temperature Monitoring During Solid Phase Processing of Materials

Internal temperature is an important parameter for understanding the solid phase processing (SPP) of materials and improving feedback control of these processes. Friction stir processes, shear assisted processing and extrusion (ShAPE ™ ), and ultrahigh velocity (UHV) cold spray are examples of such processes. Simple thermal models based on temperatures measured at the boundary of the deforming body cannot capture the dynamic nature of temperature generation within the deforming solid. One possibly way of understanding internal temperature is by measuring sound speed, which varies as a function of temperature for materials and directing ultrasonic wave propagation through selected material volumes of interest. In this project, longitudinal wave speed is estimated for aluminum 6061. Piezoelectric materials bonded to a specimen provided data from which longitudinal wave speed was estimated. A discussion evaluated the linear relationship of wave speed versus temperature and postulated how wave speed measurements could be used to estimate the internal temperature of selected material volumes for feedback during SPP of materials. Instrumentation, data and analysis, and a discussion are reviewed.

36 MATERIALS SCIENCE↗

High-Temperature Particle Heat Exchanger for sCO2 Power Cycles [Award 30342]

This report describes the design, development, and testing of a prototype 100 kWt particle-to-supercritical CO 2 (sCO2) heat exchanger. An analytic hierarchy process was implemented to compare and evaluate alternative heat-exchanger designs (fluidized bed, shell-and-plate moving packed bed, and shell-and-tube moving packed bed) that could meet the high pressure (≥ 20 MPa) and high temperature (≥ 700 °C) operational requirements associated with sCO2 power cycles. Cost, heat-transfer coefficient, structural reliability, manufacturability, parasitics and heat losses, scalability, compatibility, erosion and corrosion, transient operation, and inspection ease were considered in the evaluation. A 100 kWt shell-and-plate design was selected for construction and integration with Sandia’s falling particle receiver system that heats the particles using concentrated sunlight. Sandia worked with industry to design and construct the moving packed-bed shell-and-plate heat exchanger. Tests were performed to evaluate its performance using both electrical heating and concentrated sunlight to heat the particles. Overall heat transfer coefficients at off-design conditions (reduced operating temperatures and only three stainless steel banks in the counter-crossflow heat exchanger) were measured to be approximately ~25 - 70 W/m 2 -K, significantly lower than simulated values of >100 W/m 2 -K. Tests using the falling particle receiver to heat the particles with concentrated sunlight yielded overall heat transfer coefficients of ~35 – 80 W/m 2 -K with four banks (including a nickel-alloy bank above the three stainless steel banks). The overall heat transfer coefficient was observed to decrease with increasing particle inlet temperatures, which contrasted the results of simulations that showed an increase in heat transfer coefficient with temperature due to increased effective particle-bed thermal conductivity from radiation. The likely cause of the discrepancy was particle-flow maldistributions and funnel flow within the heat exchanger caused by internal ledges and cross-bracing, which could have been exacerbated by increased particle-wall friction at higher temperatures. Additional heat loss at higher temperatures may also contribute to a lower overall heat-transfer coefficient. Design challenges including pressure drop, particle and sCO2 flow maldistribution, and reduced heat transfer coefficient are discussed with approaches for mitigation in future designs. Lessons learned regarding instrumentation, performance characterization, and operation of particle components and sCO2 flow loops are also discussed. Finally, a 200 MWt commercial-scale shell-and-plate heat-exchanger design based on the concepts investigated in this report is proposed.

14 SOLAR ENERGY↗

Dynamics of exploding magma chambers: Implications for K-T volcanism and mass extinctions

Although it is well known that unconfined chemical explosives may yield pressures to several megabars on detonation in air, the explosive literature has yet to be accessed by some contributors to the volcanological literature who've indicated that pressures in excess of the overburden and/or tensile cannot be obtained. Idealized ballistic assessments of pressures internal to volcanoes yield pressures in the hundreds of kilobar range upon correction by addition of friction, etc. Previous assessments of exploding magma chamber pressure have been made from the characteristics of the Mt. St. Helens explosion. A variety of methods yield pressures of similar value: at least hundreds of kilobars. Such results are consistent with free energy requirements for quench supersaturation explosion, a process occurring in solidifying industrial melts. Several reviews of geochemical literature emphasize the carbon event at the Cretaceous-Tertiary (K-T) boundary as being an indicator of a massive dump of CO2 derived from the mantle and entering the atmosphere by extensive global volcanism. Oxygen isotope data indicates extreme warming at the end of the Cretaceous which is consistent with a greenhouse effect attending the CO2 event. Reaction rate equations for the quench supersaturation explosion mechanism indicated, are consistent with the rise in pressure to 30 kbar on solidification of magmatic melts, these pressures limited by the strength of the experimental apparatus.

Rice, A. R.↗

NPAC-Nozzle Performance Analysis Code

A simple and accurate nozzle performance analysis methodology has been developed. The geometry modeling requirements are minimal and very flexible, thus allowing rapid design evaluations. The solution techniques accurately couple: continuity, momentum, energy, state, and other relations which permit fast and accurate calculations of nozzle gross thrust. The control volume and internal flow analyses are capable of accounting for the effects of: over/under expansion, flow divergence, wall friction, heat transfer, and mass addition/loss across surfaces. The results from the nozzle performance methodology are shown to be in excellent agreement with experimental data for a variety of nozzle designs over a range of operating conditions.

Barnhart, Paul J.↗

Integration of scramjets with waverider configurations

This paper presents a parametric study of a scramjet propulsion system integrated into a waverider lifting-body configuration. The analysis explores the effect of inlet geometry, internal cross-section-area distribution of the combustor section, the distribution of the heat release of the reacting mixture, the heat transfer, and the friction on the performance of the propulsion system. The Mach number, temperature, and pressure distributions within the scramjet model are studied parametrically, and the effects on the thrust are obtained. The results provide insight on the design concepts and problems that might arise for a given internal-flow configuration.

Rasmussen, M. L.↗

The source of Neptune's internal heat and the value of Neptune's tidal dissipation factor

The suggestion is made that Neptune's observed internal heating is the action of tidal torques between Triton and Neptune in despinning the planet and causing the orbital decay of Triton's orbit. These result from the frictional dissipation of tides within Neptune. It is shown that the considered process implies a value of the tidal dissipation factor of approximately 170. The results of the investigation do not change the conclusion which follows from the lack of internal heating for Uranus that the interiors of Uranus and Neptune differ significantly.

Trafton, L.↗

Mid–height seismic isolation of equipment in nuclear power plants

An innovative seismic isolation solution for designers of safety-class equipment in advanced nuclear power plants is introduced. The test specimen was a tall, slender, carbon steel vessel that could represent a reactor vessel, steam generator, or a heat exchanger in a nuclear power plant: 240 inches tall, outer diameter of 60 inches, and wall thickness of 1 inch. The vessel was supported by three radial mounts at its mid-height, near its center of gravity, on a steel frame. The vessel was subjected to three-component ground motions using a 6DOF earthquake simulator. The specimen was filled with water for testing to indirectly account for the fluid and internal equipment present inside a prototype vessel. Three configurations were tested: non-isolated, isolated using single Friction Pendulum (SFP) bearings, and isolated using triple Friction Pendulum (TFP) bearings. The test results demonstrate that mid-height seismic isolation is practical and enables a significant reduction in horizontal spectral accelerations. Furthermore, these outcomes are not specific to the spherical sliding bearings used in the experiments but are broadly applicable to mid-height, seismically isolated equipment.

42 ENGINEERING↗

Multi-mesh gear dynamics program evaluation and enhancements

A multiple mesh gear dynamics computer program was continually developed and modified during the last four years. The program can handle epicyclic gear systems as well as single mesh systems with internal, buttress, or helical tooth forms. The following modifications were added under the current funding: variable contact friction, planet cage and ring gear rim flexibility options, user friendly options, dynamic side bands, a speed survey option and the combining of the single and multiple mesh options into one general program. The modified program was evaluated by comparing calculated values to published test data and to test data taken on a Hamilton Standard turboprop reduction gear-box. In general, the correlation between the test data and the analytical data is good.

Boyd, L. S.↗

Oil-Free Compressor

Compressor pistons moved by eccentric shaft need no lubricants. Compressor has shaft, middle section is eccentric in relation to end sections. Driven by brushless dc motor, shaft turns inner races of set of four cam bearings. Outer cam-bearing races in turn actuate four pistons spaced equally apart, around and along shaft. Each outer bearing race held in position by pressure exerted on it by piston. Because no frictional motion between piston and outer bearing race, lubricant between them unnecessary. Cam bearings themselves contain potted internal lubricant. Originally proposed for use in space, new compressor for refrigerators or freezers does not depend on pool of oil for lubricating its pistons. Operated in any orientation.

Fitzjerrell, D. G.↗

Flexoelectricity and New Phenomena

It is easy to miss the scientific implications of our recent work on Triboelectricity. Everyone knows that rubbing and contact can produce static electricity; less appreciated is that the thermodynamic driver has been an open question since static electricity was first observed by Thales of Miletus around 585 BC. People think they understand it, for instance one common explanation that can still be found in the current literature is that differences in the work function drives charge transfer, often called the Volta-Helmholtz hypothesis. As summarized in 1967 by Harper, this fails to explain many experimental observations, for instance that charging can occur when two pieces of the same material are rubbed against each other. We are the first to place triboelectricity on a solid foundation rooted in quantum mechanics – the flexoelectric effect. We were able to explain a significant number of previously unexplained phenomena: 1) Bipolar tribocurrents associated with stick-slip, due to the change in sign of the strain gradients. 2) A one-third power scaling of tribocurrents with indentation force. 3) Tribocharging when two identical materials are used, these being due to local variations in the asperities so there are usually local potential differences. 4) Inhomogeneous charging of insulators, related to the statistical nature of asperities. 5) An experimentally observed reversal in the sign of charge transfer for negative and positive curvature, which is related to a change in the sign of the strain gradient. Exploiting our DOE prior funded work on flexoelectricity, we obtained semi-quantitative matching to existing experimental measurements of the surface charge in triboelectric experiments. The work has been well received in the literature. The work has been the focus of a number of popular science press articles, and also formed the basis for a Podcast for children 6-10 “The Rise and Fall of Static Man” posted in December 2019 by NPR as part of their “Wow in the World” series. I was also briefly interviewed by the Chicago PBS station in January 2020. This work are significant for a wide range of energy applications; to quote from an independent source: "Triboelectric power has plenty of potential, says Wenzhuo Wu, an assistant professor of engineering at Purdue. If the basics of static electricity are better understood, we could maximize the efficiency of wind or wave power generators, Wu says. The body's own movement could be used to power internal medical devices. Imagine being able to create a roof shaped to harness the power of a raindrop — the friction of the rain passing over the surface — to generate triboelectricity, powering the building below it." This is the start of new science, some of which we already partially understand such as the role of band bending in charge transfer. We need to understand charge transfer combining elasticity, quantum mechanics, band bending and defect states. These directly involve several of the DOE Grand Challenges: "How do we control material processes at the level of electrons? How do remarkable properties of matter emerge from complex correlations of the atomic or electronic constituents and how can we control these properties? How do we characterize and control matter away—especially very far away— from equilibrium?" I will argue that this work truly falls into the class of disruptive science; it is not just a simple extension, linear science. Not everyone will accept the approach. Since we explain far more about triboelectricity than anyone before, the preponderance of evidence supports the model. The feedback I have received is that many agree with the work, to quote: "The model makes sense, says Michael McAlpine, a professor of engineering at the University of Minnesota. "It's such a simple explanation, I was surprised I didn't put my finger on that," McAlpine says." The proposal received strong reviews. It was also publicized on the Department of Energy Web Site.

16 TIDAL AND WAVE POWER↗

Characterization of superfluid helium transfer

The friction factor and steady state flow rate of superfluid helium (He II) are measured, with the driving pressure difference generated by the saturated vapor pressure and a small hydrostatic pressure head. The temperature ranged from 1.5 K to the transition temperature of 2.17 K. Three different lengths and two different internal diameters were used for the stainless steel transfer tubes, and the transfer of liquid helium (He I) was investigated with the same apparatus for comparison. It was found that the friction factor of He II is greater than that of He I for pressure differences greater than 20 mm Hg, and smaller below that magnitude.

Yang, L. C.↗