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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗
NASA NTRS2024

Enhancing Future Commercial Space Stations: Applying ISS Insights to Environmental Control and Life Support Systems (ECLSS) Development

The expansion of space exploration to commercial space stations represents a shift from government-led endeavors to a new competitive era driven by private companies and innovative forces. The journey to actualize these celestial outposts is fraught with difficulties, including the intricate establishment of Environmental Control and Life Support systems (ECLSS) within these commercial space stations. By applying the insights gleaned from the ISS, particularly during the initial conceptual design phase of the commercial developments, there is an opportunity to circumvent some of the teething issues and optimize the development process. Furthermore, applying insights from the ISS ECLSS design, development, test, and maintenance phases has the potential to enhance system compatibility and mitigate the challenges associated with upgrading a fixed design. This approach can lead to lower costs due to fewer iterations and streamlined processes. This paper will conduct an in-depth evaluation of the ECLS system from both system and operational perspectives with the aim to provide a knowledge capture for early-stage design considerations to bolster the development of sustainable, efficient, and habitable commercial space stations.

ISS↗
NASA NTRSDate not supplied

Enhancing Future Commercial Space Stations: Applying ISS Insights to Environmental Control and Life Support Systems (ECLSS) Development

The expansion of space exploration to commercial space stations represents a shift from government-led endeavors to a new competitive era driven by private companies and innovative forces. The journey to actualize these celestial outposts is fraught with difficulties, including the intricate establishment of Environmental Control and Life Support systems (ECLSS) within these commercial space stations. By applying the insights gleaned from the ISS, particularly during the initial conceptual design phase of the commercial developments, there is an opportunity to circumvent some of the teething issues and optimize the development process. Furthermore, applying insights from the ISS ECLSS design, development, test, and maintenance phases has the potential to enhance system compatibility and mitigate the challenges associated with upgrading a fixed design. This approach can lead to lower costs due to fewer iterations and streamlined processes. This paper will conduct an in-depth evaluation of the ECLS system from both system and operational perspectives with the aim to provide a knowledge capture for early-stage design considerations to bolster the development of sustainable, efficient, and habitable commercial space stations.

ISS↗
NASA NTRS1984

Design versus manufacturing data base management requirements

Data base management systems are valuable manufacturing and design tools as these disciplines are exceptionally information intensive, requiring precise organization and control of data processing and utilization. One such data base manager is the IPAD* system, which was originally developed to support the design process but was expanded to incorporate the additional needs of manufacturing. To set the stage, an overview of the design and manufacturing process is presented. The different functions of computers in these processes are then discussed. Finally, the design and manufacturing requirements for a data base manager are compared and contrasted.

Mckenna, E. G.↗
DOE OSTI2021

Thermodynamic modeling of the Ti-Nb-Sn system and its preliminary applications in aging precipitation and solidification simulations

Abstract Gasping the thermodynamic and phase diagram of the materials being studied is essential for further guiding the development process, like composition design, heat treatment optimization and so on. Nb and Sn are common alloying elements in Ti-based biomedical alloys. In this work, the Ti-Nb-Sn system has been thermodynamically assessed based on experimental phase equilibria. A self-consistent thermodynamic description for the Ti-Nb-Sn system including two ternary compounds Ti 3 Nb 3 Sn 2 and Ti 3 NbSn has been obtained. Based on the comparison between the calculated and experimental phase equilibria, the reliability of the presently obtained thermodynamic description has been verified. The influence of Nb and Sn contents on the precipitation temperature and amount of hcp α -Ti phase in bcc β -(Ti, Nb) has been investigated based on thermodynamic calculations. Results show that the increase of Nb or Sn content in Ti-based alloys would significantly reduce the precipitation amount and transformation temperature of hcp α -Ti phase in bcc β -(Ti, Nb) and the influence of Nb content is more effective than that of Sn. The solidified phases in several as-cast alloys have been thermodynamically predicted based on Scheil solidification simulations. The presently developed thermodynamic description of the Ti-Nb-Sn system can serve as a sub-ternary one in the thermodynamic database for multicomponent Ti-based biomedical alloys.

Peng, Yingbiao↗
NASA NTRS2011

Integration of Off-Track Sonic Boom Analysis in Conceptual Design of Supersonic Aircraft

A highly desired capability for the conceptual design of aircraft is the ability to rapidly and accurately evaluate new concepts to avoid adverse trade decisions that may hinder the development process in the later stages of design. Evaluating the robustness of new low-boom concepts is important for the conceptual design of supersonic aircraft. Here, robustness means that the aircraft configuration has a low-boom ground signature at both under- and off-track locations. An integrated process for off-track boom analysis is developed to facilitate the design of robust low-boom supersonic aircraft. The integrated off-track analysis can also be used to study the sonic boom impact and to plan future flight trajectories where flight conditions and ground elevation might have a significant effect on ground signatures. The key enabler for off-track sonic boom analysis is accurate computational fluid dynamics (CFD) solutions for off-body pressure distributions. To ensure the numerical accuracy of the off-body pressure distributions, a mesh study is performed with Cart3D to determine the mesh requirements for off- body CFD analysis and comparisons are made between the Cart3D and USM3D results. The variations in ground signatures that result from changes in the initial location of the near-field waveform are also examined. Finally, a complete under- and off-track sonic boom analysis is presented for two distinct supersonic concepts to demonstrate the capability of the integrated analysis process.

Ordaz, Irian↗
NASA NTRS1991

Cost studies for commercial fuselage crown designs

Studies were conducted to evaluate the cost and weight potential of advanced composite design concepts in the crown region of a commercial transport. Two designs from each of three design families were developed using an integrated design-build team. A range of design concepts and manufacturing processes were included to allow isolation and comparison of cost centers. Detailed manufacturing/assembly plans were developed as the basis for cost estimates. Each of the six designs was found to have advantages over the 1995 aluminum benchmark in cost and weight trade studies. Large quadrant panels and cobonded frames were found to save significant assembly labor costs. Comparisons of high- and intermediate-performance fiber systems were made for skin and stringer applications. Advanced tow placement was found to be an efficient process for skin lay up. Further analysis revealed attractive processes for stringers and frames. Optimized designs were informally developed for each design family, combining the most attractive concepts and processes within that family. A single optimized design was selected as the most promising, and the potential for further optimization was estimated. Technical issues and barriers were identified.

Walker, T. H.↗
DOE OSTI2021

Electricity Market of the Future: Potential North American Designs Without Fuel Costs

Electricity markets across the United States and Canada have evolved since their inception in the late 1990s and early 2000s. Not all states and provinces moved toward restructured organized electricity markets, but rather those that have belonged to markets operated by independent system operators (ISOs) and regional transmission organizations, with designs developed through stakeholder processes and approved through state, provincial, or federal agencies, such as the Federal Energy Regulatory Commission (FERC).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Mapping the Opportunity Space to Model the Circular Economy Using Tools Funded by the DOE Office of Energy Efficiency and Renewable Energy

An increasing rate of material consumption and a growing population mean that the Earth's supply of natural resources is witnessing an unsustainable and unprecedented demand. This forces us to find solutions that ensure the availability of resources for sustenance of our society in the years to come. Actors from various backgrounds are addressing these challenges from their own perspectives: engineers are developing efficient manufacturing processes, designers are creating lightweight and durable products, educators are incorporating sustainable thinking in their curricula, policymakers are finding interdisciplinary solutions that benefit society at large, etc. Circular economy (CE) is one such approach to resource use that aims to move away from the linear material use framework of "take-make-waste" to a more circular and interdependent system where product, material and resource use is maximized to avoid unnecessary social, economic, and environmental costs. The purpose of this report is to explain how to approach evaluating the circular economy and to help researchers identify existing tools that can be used or that can serve as starting points for their research needs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Princeton University (Abstract)

The National Energy Technology Laboratory (NETL) and Princeton University will collaborate in the development of microwave-plasma technology to convert methane into hydrogen and valuable solid carbon materials. The effort will combine NETL’s vast resources for microwave-enhanced process development, characterization, and design with Princeton University’s extensive expertise in the study of non-equilibrium plasmas employing supersonic nozzles. Lab-scale experiments will be conducted for different conditions to convert and compare their respective performance in hydrogen production. Computational modeling will be performed to verify results from experimental studies conducted in both labs.

08 HYDROGEN↗
DOE OSTI2022

Low Regeneration Temperature Sorbents for Direct Air Capture of CO 2

Susteon Inc., in partnership with University of Wyoming and SoCalGas, successfully met all major technical objectives to (1) scale up the ionic liquid catalyst for amine-based sorbents for improved desorption and absorption kinetics, (2) evaluate the catalyzed amine-based sorbents for direct CO 2 capture process to determine CO 2 adsorption and desorption rates and energy requirements, and (3) based on the experimental results, develop a conceptual process design to perform a preliminary economic assessment to evaluate the potential for DAC process cost reduction using the catalyzed sorbents. Amine doped solid sorbents are effective for DAC applications and can be regenerated by heat or by a combination of heat, steam, and vacuum. The best sorbent composition identified was polyethyleneimine (PEI) on fumed silica with 200 ppm ionic liquid catalyst. This sorbent formulation was shown to have a CO 2 breakthrough capacity twice that of the non-catalyzed sorbent, in laboratory tests with air at 75% relative humidity (RH). The CO 2 adsorption rate was also 40% higher than that of the non-catalyzed sorbent. This type of sorbents has the attributes required for lowering the overall cost of DAC with high CO 2 capacity and high rate of adsorption. The combination of an industrially utilized amine-based sorbent with a highly active catalyst to form a new class of materials for DAC provides a technically viable pathway for reducing the cost of DAC to <$100/tonne of CO 2 . Laboratory measurements show that the silica/PEI (polyethyleneimine) sorbents with 100 ppm of ionic liquid catalyst have almost 100% higher CO 2 cyclic capacity and 40% higher adsorption rate. Generally, CO 2 desorption occurred at higher temperatures with a rate of desorption 10 times faster than adsorption (which occurred at ambient conditions). Therefore, adsorption rate is a much more important factor in the cost of DAC because it is directly linked to the CAPEX of the total system and the cycle time (i.e., sorbent productivity in ton/day of CO 2 captured per unit volume of the air contactor). An initial process design, coupled with techno-economic analysis, based on optimal experimental results and preliminary resulting from structured sorbent testing, showed a path to lower the DAC cost from the current cost of over $200/tonne CO 2 to less than $100/tonne with a scale-up, mature state of the technology, with projected material and process improvements. These results demonstrate the effectiveness of the catalyst in silica/PEI sorbents in enhancing sorbents’ CO 2 working capacity, in (a) increasing the rate of adsorption and desorption, and (b) in lowering the CAPEX and OPEX of the DAC system employing the ionic liquid catalyzed sorbents.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays

This is the final technical report for the Virginia Tech Center for Photonics Technology (VT-CPT) research project entitled “Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays”. In the the four-year effort, VT-CPT collaborated with the Departments of Mathmatics at VT and Sentek Instrument, LLC (Sentek) to develop a fiber-optic sensing system capable of real-time simultaneous distributed measurement of multiple subsurface, drilling, and production parameters. The ultra-sensitive fiber optic distributed acoustic sensing technology, picoDAS, developed by Sentek was integrated with a novel multi-material optical sensing fiber fabricated by CPT-VT to obtain distributed acoustic and magnetic field measurements with ultrahigh sensitivity and high spatial resolution. The sensing technology successfully developed and demonstrated under this research program is truly unique has application beyond subsurface imaging to include carbon storage and electrical grid monitoring, as well as healthcare and nuclear fusion. The project, sponsored by the Advanced Technology Program, began in 2019 and had the original goal of developing the next generation of harsh environment sensing systems. Exhaustive theoretical modeling was performed to optimize the multi-material optical fiber design. VT developed the processing techniques employed to successfully fabricate single mode fibers with metal cladding wires. Sensing fibers with nickel and Metglas cladding wires were fully characterized, inscribed with sensors, and fully integrated with the picoDAS system. Laboratory scale testing was performed to demonstrate performance upon exposure to lateral and transverse magnetic fields. Preliminary field trials were performed for prototype magnetic and acoustic sensing systems upon near surface deployment at VT. The distributed acoustic and magnetic field sensing system was advanced from a (Technology Readiness Level) TRL=2 to a TRL=5 via laboratory scale system validation in relevant environments. The truly one-of-its kind distributed magnetic and acoustic sensing system is expected to find immediate applications that require subsurface monitoring, to include carbon storage site monitoring, and has the potential to be a distributive technology in healthcare and electric grid markets. The technologies developed by Virginia Tech’s Center for Photonics Technology will support the mission of the National Energy Technology Laboratory (NETL) to drive innovation and deliver solutions for an environmentally sustainable and prosperous energy future by ensuring affordable, abundant, and reliable energy that drives a robust economy and national security. Technical accomplishments during the program are summarized briefly here and described in detail in the remainder of the report.

02 PETROLEUM↗
NASA NTRS1973

Fabrication techniques for polybenzimidazole composites

Performance of polybenzimidazole composites as ablation shields can be substantially improved by thermal crosslinking. Program was designed to develop new processing methods and techniques for fabrication of polybenzimidazole composites. Report, which describes fabrication in detail, also includes specification and manufacturing standards.

Parker, J. A.↗
NASA NTRS1974

Operational aspects of Skylab

Attention is given to the salient features of Skylab design and the development process in order to illustrate how they influenced the flight operations. Organizational questions are considered, giving attention to the functions of the flight management team, the conduction of the flight operations by the Mission Operations Team, details regarding the engineering support organization, and aspects of science support.

Hanes, T. E.↗
NASA NTRS1975

Program planning, chapter 5, part D

Recommendations for future activities necessary to support satellite microwave sensing are reported. Areas covered include component development, data processing, calibration, design and fabrication of multifrequency systems, and experimental test programs to establish interactions of electromagnetic waves and sensed parameters.

Source record↗
NASA NTRS1987

Color postprocessing for 3-dimensional finite element mesh quality evaluation and evolving graphical workstation

Three general tasks on general-purpose, interactive color graphics postprocessing for three-dimensional computational mechanics were accomplished. First, the existing program (POSTPRO3D) is ported to a high-resolution device. In the course of this transfer, numerous enhancements are implemented in the program. The performance of the hardware was evaluated from the point of view of engineering postprocessing, and the characteristics of future hardware were discussed. Second, interactive graphical tools implemented to facilitate qualitative mesh evaluation from a single analysis. The literature was surveyed and a bibliography compiled. Qualitative mesh sensors were examined, and the use of two-dimensional plots of unaveraged responses on the surface of three-dimensional continua was emphasized in an interactive color raster graphics environment. Finally, a postprocessing environment was designed for state-of-the-art workstation technology. Modularity, personalization of the environment, integration of the engineering design processes, and the development and use of high-level graphics tools are some of the features of the intended environment.

Panthaki, Malcolm J.↗