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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 235 records · Page 13

All sources NASA NTRS DOE OSTI

NASA NTRS1986

Composite load spectra for select space propulsion structural components

A multiyear program is performed with the objective to develop generic load models with multiple levels of progressive sophistication to simulate the composite (combined) load spectra that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades, and liquid oxygen (LOX) posts. Progress of the first year's effort includes completion of a sufficient portion of each task -- probabilistic models, code development, validation, and an initial operational code. This code has from its inception an expert system philosophy that could be added to throughout the program and in the future. The initial operational code is only applicable to turbine blade type loadings. The probabilistic model included in the operational code has fitting routines for loads that utilize a modified Discrete Probabilistic Distribution termed RASCAL, a barrier crossing method and a Monte Carlo method. An initial load model was developed by Battelle that is currently used for the slowly varying duty cycle type loading. The intent is to use the model and related codes essentially in the current form for all loads that are based on measured or calculated data that have followed a slowly varying profile.

Newell, J. F.↗

DOE OSTI2023

Wind Fields in Category 1–3 Tropical Cyclones Are Not Fully Represented in Wind Turbine Design Standards

Abstract Offshore wind energy deployment in the U.S. is expected to increase in the years to come, with proposed wind farm sites located in regions with high risk for tropical cyclones. Yet, the wind turbine design criteria outlined by the International Electrotechnical Commission for extreme events may not account for wind field characteristics unique to tropical cyclones. To evaluate if current design standards capture the extreme conditions of these storms, we perform idealized large‐eddy simulations of three tropical cyclones (one Category 1, one Category 2, and one Category 3 storms) using the Weather Research and Forecasting model. Wind conditions near the eyewall of Cat‐1, Cat‐2, and Cat‐3 storms can exceed current design standards for offshore wind turbines. Winds at 90 m can be faster than outlined in the design criteria for Class I and Class T turbines for 50‐year recurrence periods. Wind speed shear across the turbine rotor layer is also larger than assumed in design specifications. Moreover, vertical variations in wind direction across the turbine rotor layer are large for tropical cyclones of all intensity levels, suggesting design standards should include veer, which can amplify loads in wind turbines. The existence of hurricane wind field characteristics that are not represented in design standards does not imply that damage or failure will certainly occur. Engineering safety factors incorporated in the design of the turbine's blades and structural components may prevent damage from occurring.

17 WIND ENERGY↗

NASA NTRS1982

Evaluation of shear mounted elastomeric damper

Viton-70 elastomeric shear mounted damper was built and tested on a T-55 power turbine spool in the rotor's high speed balancing rig. This application of a shear mounted elastomeric damper demonstrated for the first time, the feasibility of using elastomers as the primary rotor damping source in production turbine engine hardware. The shear damper design was selected because it was compatible with actual gas turbine engine radial space constraints, could accommodate both the radial and axial thrust loads present in gas turbine engines, and was capable of controlled axial preload. The shear damper was interchangeable with the production T-55 power turbine roller bearing support so that a direct comparison between the shear damper and the production support structure could be made. Test results show that the Viton-70 elastomer damper operated successfully and provided excellent control of both synchronous and nonsynchronous vibrations through all phases of testing up to the maximum rotor speed of 16,000 rpm. Excellent correlation between the predicted and experienced critical speeds, mode shapes and log decrements for the power turbine rotor and elastomer damper assembly was also achieved.

Zorzi, E.↗

NASA NTRS1978

Effects of rotor location, coning, and tilt on critical loads in large wind turbines

Several large (1500 kW) horizontal rotor configurations were analyzed to determine the effects on dynamic loads of upwind downwind rotor locations, coned and radial blade positions, and tilted and horizontal rotor axis positions. Loads were calculated for a range of wind velocities at three locations in the structure: (1) the blade shank; (2) the hub shaft; and (3) the yaw drive. Blade axis coning and rotor axis tilt were found to have minor effects on loads. However, locating the rotor upwind of the tower significantly reduced loads at all locations analyzed.

Spera, D. A.↗

NASA NTRS2004

Integrity of Ceramic Parts Predicted When Loads and Temperatures Fluctuate Over Time

Brittle materials are being used, and being considered for use, for a wide variety of high performance applications that operate in harsh environments, including static and rotating turbine parts for unmanned aerial vehicles, auxiliary power units, and distributed power generation. Other applications include thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and microelectromechanical systems (MEMS). In order for these high-technology ceramics to be used successfully for structural applications that push the envelope of materials capabilities, design engineers must consider that brittle materials are designed and analyzed differently than metallic materials. Unlike ductile metals, brittle materials display a stochastic strength response because of the combination of low fracture toughness and the random nature of the size, orientation, and distribution of inherent microscopic flaws. This plus the fact that the strength of a component under load may degrade over time because of slow crack growth means that a probabilistic-based life-prediction methodology must be used when the tradeoffs of failure probability, performance, and useful life are being optimized. The CARES/Life code (which was developed at the NASA Glenn Research Center) predicts the probability of ceramic components failing from spontaneous catastrophic rupture when these components are subjected to multiaxial loading and slow crack growth conditions. Enhancements to CARES/Life now allow for the component survival probability to be calculated when loading and temperature vary over time.

Nemeth, Noel N.↗

DOE OSTI2020

Bichromatic Wave Selection for Validation of the Difference-Frequency Transfer Function for the OC6 Validation Campaign: Preprint

The focus of the Offshore Code Comparison Collaboration, Continuation, with Correlation and unCertainity (OC6) project, which operates under the International Energy Agency (IEA) Wind Task 30, is to refine the accuracy of engineering tools used to design offshore wind turbines. In support of this work, a new validation campaign is being developed that seeks to better understand the nonlinear wave loading that excites floating wind systems at their low-frequency, rigid-body modes in surge and pitch. The validation data will be used in a three-way validation between simplified engineering tools and higher-fidelity tools, such as computational fluid dynamics (CFD). Irregular wave spectrums, which are traditionally used to examine the nonlinear wave interaction with offshore structures, are too computationally expensive to be simulated in CFD tools, and so bichromatic wave cases will be used instead. This paper reviews the process used to choose the bichromatic wave pairs to be used in the campaign to validate the second-order difference-frequency quadratic and potential loads at the surge and pitch natural frequencies of a floating semisubmersible.

17 WIND ENERGY↗

DOE OSTI2024

Performance data for an axial-flow turbine with passive adaptive blades

To support the development of simulation tools for passive adaptive turbine rotors, an experimental data set from a laboratory-scale axial-flow turbine with passive adaptive blades is provided. The 0.45-meter diameter turbine was tested in the Alice C. Tyler Flume at the University of Washington. Blade and rotor loads were measured at 1 kHz using six-axis force/torque sensors while deflection and twist at the blade tip were tracked using a high-speed camera. This data submission includes a technical report, the raw and processed experimental data, and a README file explaining the file/folder structure and where to find the processing/plotting scripts used to produce the figures in the technical report.

16 TIDAL AND WAVE POWER↗

NASA NTRS1977

Effects of rotor location, coning, and tilt on critical loads in large wind turbines

Three large (1500 kW) horizontal rotor configurations were analyzed to determine the effects on dynamic loads of upwind and downwind rotor locations, coned and radial blade positions, and tilted and horizontal rotor axis positions. Loads were calculated for a range of wind velocities at three locations in the structure: the blade shank, the hub shaft, and the yaw drive. Blade axis coning and rotor axis tilt were found to have little effect on loads. However, locating the rotor upwind of the tower significantly reduced loads at all locations analyzed.

Spera, D. A.↗

NASA NTRSDate not supplied

Development of an Additively Manufactured Turbine Blade Tuned Mass Absorber

An innovative concept using a tuned mass absorber for resonant response reduction of turbine blades that is integrally fabricated into the blades using additive manufactured has been developed. Avoiding high resonant response and resulting high cycle fatigue failure is a major concern of the $100B worldwide turbine industry, which encompasses power generation, jet engines and rocket engine turbomachinery. Blade failure is potentially catastrophic, and although preventative measures using dampers do exist, these solutions are extremely expensive to develop and are not always effective. In addition, many of the existing techniques do not work for newer integrally bladed disks (or blisks), where there is no inherent damping in the assembly. The proposed concept, in which a tuned mass absorber re-arranges the structural dynamics and moves energy from the blade to the absorber, is designed specifically for blisks, and is intentionally linear, enabling accurate response prediction during design. Single blade prototypes have been analyzed, fabricated, and tested, and different absorber concepts have shown a reduction in response of up to 60%. After an extensive commercialization and prior art search, MSFC determined the innovation merited the generation and submission of a patent application in August ’21. Funding is now being sought to fabricate a 20-bladed blisk which would be spun at operational speeds with substantially higher and more realistic pressure loads in a special spin facility. Successful completion of this program would raise the TRL from 3/4 to 6/7, significantly improving the viability for adoption of the concept not only in rocket engines but other industrial applications as well.

Turbine Blades↗

DOE OSTI2020

Gravo-aeroelastic scaling of a 13-MW downwind rotor for 20% scale blades

A 105-m, 13-MW two-bladed downwind Segmented Ultralight Morphing Rotor (SUMR-13) blade was gravo-aeroelastically scaled by 20% to a 20.87-m-long demonstrator blade and confirmed through structural ground testing. The subscale model was achieved through geometric scaling and by aeroelastic scaling principles based on operational flapwise deflections combined with rotational and structural frequencies while retaining the turbine tip-speed ratio. In particular, the subscale demonstrator was designed to replicate, as closely as possible, the nondimensional geometry, the ratio of centrifugal to gravitational moments, the tip-speed ratio, and the nondimensional rotation rate. The intent for this demonstrator was to achieve the same nondimensional flapwise blade deflections and dynamics of the full-scale 13-MW rotor. The manufactured SUMR-D blade resulted in less than half of the mass of the conventional two-bladed Controls Advanced Research Turbine (CART2) rotor blade based on scaling and a lower power rating, though with some differences in mass and stiffness from the ideal scaled-down design to meet safety requirements at the test site. To achieve proper scaling, operational pitch control set points were altered to account for the differences by evaluating simulated operation of both the SUMR-13 and SUMR-D rotors. Structural testing of the SUMR-D blade investigated the response to well-defined flapwise loads and indicated that the subscale blade had the appropriate elastic properties needed for both scaling and for safe operational field testing.

17 WIND ENERGY↗

NASA NTRS2008

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗

DOE OSTI2021

UNH TDP - Load Cell Raw Data and Processing Scripts - Fall 2021

This submission contains raw Load Cell data and processing scripts associated with MHKDR submission 394 (UNH TDP - Concurrent Measurements of Inflow, Power Performance, and Loads for a Grid-Synchronized Vertical Axis Cross-Flow Turbine Operating in a Tidal Estuary, DOI: 10.15473/1973860) from the University of New Hampshire and Atlantic Marine Energy Center (AMEC) turbine deployment platform. The user is directed to the MHKDR submission 394 for relevant context and detail of this deployment; see link below. The 394_READ_ME file here provides the description from that submission for quick reference. The READ_ME file for this specific instrument from the 394 submission is also available here. This submission contains a zipped folder structure containing raw data in its original format and MATLAB (2019a) processing scripts used to process and manipulate the data into its final form. The final data products are submitted in the 394 submission.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

REopt Lite Overview & Training Exercise

This training exercise provides users with an introduction to and hands-on, interactive exploration of REopt Lite's capabilities. REopt Lite is a free, publicly available techno-economic optimization web tool for distributed energy systems, developed at the National Renewable Energy Laboratory (NREL). REopt Lite helps organizations evaluate the economic viability of grid-connected solar photovoltaics (PV), wind turbines, and battery storage; identify system sizes and battery dispatch strategies to minimize energy costs; and estimate how long a system can sustain critical load during a grid outage. The model is formulated as a mixed-integer linear program based in an underlying application programming interface (API) that is also free and publicly available. This training activity is structured as a group exercise. Participants split into eight groups and each group is assigned a different hypothetical site to model and assess the opportunity for solar PV + battery storage. Groups work together to develop results for their site and then re-convene to compare and discuss results, inputs/drivers of the analysis, and other factors impacting the decision-making process for behind-the-meter solar PV and battery storage.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1981

Elevated temperature fatigue testing of metals

Material characterization and evaluation conducted for the purpose of calculating fatigue crack initiation lives of components operating at elevated temperatures are discussed. The major technology areas needed to perform a life prediction of an aircraft turbine engine hot section component and the steps required for life prediction are outlined. These include: the determination of the operating environment, the calculation of the thermal and mechanical loading of the component, the cyclic stress strain and creep behavior of the material required for structural analysis, the structural analysis to determine the local stress strain temperature time response of the material at the critical location in the component, and from a knowledge of the fatigue, creep, and failure resistance of the material, a prediction of the life of the component.

Hirschberg, M. H.↗

NASA NTRS1984

Vibration characteristics of the HPOTP (High-Pressure Oxygen Turbopump) of the SSME (Space Shuttle Main Engine)

Attention is given to rotor dynamic problems that have been encountered and eliminated in the course of Space Shuttle Main Engine (SSME) development, as well as continuing, subsynchronous problems which are being encountered in the development of a 109-percent power level engine. The basic model for the SSME's High Pressure Oxygen Turbopump (HPOTP) encompasses a structural dynamic model for the rotor and housing, and component models for the liquid and gas seals, turbine clearance excitation forces, and impeller diffuser forces. Linear model results are used to examine the synchronous response and stability characteristics of the HPOTP, with attention to bearing load and stability problems associated with the second critical speed. Differences between linear and nonlinear model results are discussed and explained in terms of simple models. Simulation results indicate that while synchronous bearing loads can be reduced, subsynchronous motion is not eliminated by seal modifications.

Childs, D. W.↗

NASA NTRS1996

Thermomechanical Multiaxial Fatigue Testing Capability Developed

Structural components in aeronautical gas turbine engines typically experience multiaxial states of stress under nonisothermal conditions. To estimate the durability of the various components in the engine, one must characterize the cyclic deformation and fatigue behavior of the materials used under thermal and complex mechanical loading conditions. To this end, a testing protocol and associated test control software were developed at the NASA Lewis Research Center for thermomechanical axial-torsional fatigue tests. These tests are to be performed on thin-walled, tubular specimens fabricated from the cobalt-based superalloy Haynes 188. The software is written in C and runs on an MS-DOS based microcomputer.

Source record↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

gearbox↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems: Preprint

ENGINEERING,WIND ENERGY↗