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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Melting temperature measurement of refractory oxide ceramics as a function of oxygen fugacity using containerless methods

An aerodynamic conical nozzle levitator (CNL) has been used to measure the melting temperatures of refractory ceramics. The well-established method of cooling traces has been adapted to allow measurements for air-sensitive samples using a controlled atmosphere, where the oxygen partial pressure can be adjusted and monitored in real time. In this study, we explain the details of a system that we developed for use at the Spallation Neutron Source (Oak Ridge National Laboratory). Measurements of the melting behavior of (Fe,Cr,Al) 3 O 4 spinels were made between log (PO 2 (atm)) of -0.7 and -5. The melting temperature of hercynite is found to be oxygen potential dependent, ranging between 1692 and 1767°C at log (PO 2 ) values from -4.42 to -0.70.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The structure of CaO–MgO–Al 2 O 3 –SiO 2 melts and glasses doped with FeO X –NiO

Neutron and x-ray diffraction measurements have been performed on CaO–MgO–Al 2 O 3 –SiO 2 (CMAS) glasses doped with NiO–Fe X O at room temperature, along with x-ray measurements on aerodynamically levitated liquids at ≥2000 K. The disordered structures have been modeled using empirical potential structure refinement to investigate the relation between the aluminosilicate network and the modifying cations. The SiO 4 and AlO 4 tetrahedra are found to have wider Si–O and Al–O bond distance distributions in the glass, and the first Ca–O n coordination shell is highly distorted, redistributing different populations of long and short bonds between the liquid and the glass. The addition of Fe and Ni at low aluminosilicate content increases the number of free oxygens not bonded to AlO 4 or SiO 4 . Mg–O and Fe–O are both found to be predominantly fourfold and fivefold in the liquid and glassy states. Despite these low coordination numbers, their bond angle distributions indicate that they are predominantly in nontetrahedral-type geometries, with ferrous and ferric iron possessing similar coordination environments. The Ca–O and Mg–O average coordination numbers and enthalpies of solution are consistent with their higher reactivity within relatively acidic aluminosilicate melts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Melting point of group IV and V transition metal diborides

The environmental conical nozzle levitator system enables cooling trace experiments above 4000 K. These cooling trace experiments were used to determine the melting points through observation of thermal arrest of group IV and V transition metal diborides (TiB 2 , T m = 3313 ± 33 K; ZrB 2 , T m = 3404 ± 38 K; HfB 2 , T m = 3529 ± 33 K; and TaB 2 , T m = 3284 ± 10 K; note: mean ± 2 standard error). Temperature measurements were conducted utilizing dual single-color pyrometers at wavelengths of 0.9 and 0.65 µm. This system utilizes aerodynamic levitation and dual laser heating to achieve temperatures approaching 4000 K. The samples were synthesized from commercial powders using ceramic gel-casting to produce high-density spherical components. The measurements obtained were compared to previously reported melting temperature values and were generally found to be in agreement with most of the published values.

Materials science↗
DOE OSTI2020

Optimizing Piezoelectric Material Location and Size for Multiple-Mode Vibration Reduction of Turbomachinery Blades

Modern turbomachinery blades have extremely low inherent damping, which can lead to high transient vibrations and failure through high-cycle fatigue. Smart materials enable vibration reduction while meeting strict blade requirements such as weight and aerodynamic efficiency. In particular, piezoelectric-based vibration reduction offers the potential to reduce vibration semi-actively while simultaneously harvesting sufficient energy to power the implementation. The placement and the size of the piezoelectric material is critical to the vibration reduction capabilities of the system. Furthermore, the implementation should target multiple vibration modes. In this study, we develop a procedure to optimize electromechanical coupling across multiple vibration modes for a representative turbomachinery blade with surface-mounted piezoelectric patches. Experimental validation demonstrates good coupling across three targeted modes with a single piezoelectric patch. Placing the piezoelectric material in regions of high signed strain energy for all targeted modes enables vibration reduction across all of the targeted modes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Inverse Design of Two-Dimensional Airfoils Using Conditional Generative Models and Surrogate Log-Likelihoods

Abstract This paper shows how to use conditional generative models in two-dimensional (2D) airfoil optimization to probabilistically predict good initialization points within the vicinity of the optima given the input boundary conditions, thus warm starting and accelerating further optimization. We accommodate the possibility of multiple optimal designs corresponding to the same input boundary condition and take this inversion ambiguity into account when designing our prediction framework. To this end, we first employ the conditional formulation of our previous work BézierGAN–Conditional BézierGAN (CBGAN)—as a baseline, then introduce its sibling conditional entropic BézierGAN (CEBGAN), which is based on optimal transport regularized with entropy. Compared with CBGAN, CEBGAN overcomes mode collapse plaguing conventional GANs, improves the average lift-drag (Cl/Cd) efficiency of airfoil predictions from 80.8% of the optimal value to 95.8%, and meanwhile accelerates the training process by 30.7%. Furthermore, we investigate the unique ability of CEBGAN to produce a log-likelihood lower bound that may help select generated samples of higher performance (e.g., aerodynamic performance). In addition, we provide insights into the performance differences between these two models with low-dimensional toy problems and visualizations. These results and the probabilistic formulation of this inverse problem justify the extension of our GAN-based inverse design paradigm to other inverse design problems or broader inverse problems.

Engineering↗
DOE OSTI2022

Effect of the J-Shaped Wind Turbine Airfoil Opening Ratio and Thickness on the Performance of Symmetrical Airfoils

Abstract In this work, the effect of the inner opening ratio on the J-shaped airfoils aerodynamic performance was studied and documented for symmetrical airfoils. Three different airfoil thicknesses were investigated: small (NACA0008), medium (NACA0015), and large (NACA0024). For each airfoil thickness, effects of three inner opening ratios were analyzed: one-third, one-half, and two-thirds. The performance of each opening ratio was compared with the performance of the solid airfoil “zero opening ratio” for different angles of attack between 5 deg and 20 deg. All designs were simulated using the computational fluid dynamics (CFD) technology against experimental results for solid NACA4412 airfoil in the University of Wisconsin-Milwaukee (UWM) wind tunnel facility and other published experimental data. It was found that large eddy simulation yields accurate solutions with a smaller number of mesh cells compared to the k–ω turbulence model but with much longer computational time. The lift-to-drag ratio for all studied airfoils has a maximum value for solid airfoils compared to those equipped with openings. For airfoils equipped with 00.00% opening ratio “solid,” NACA0015 airfoil has the maximum lift-to-drag ratio. Furthermore, it was found that NACA0008 equipped with a 33.33% opening ratio has the best performance of all studied J-shaped airfoils.

Energy & Fuels↗
DOE OSTI2023

Large Eddy Simulation of Gasoline Sprays in a Lagrangian–Eulerian Framework Using the High-Order Spectral Element Method

Predicting the spray evolution using simulations requires accurate modeling of the turbulent gas-phase flow field. Here, in this study, the high-order spectral-element method (SEM), implemented in the code Nek5000, was used to provide highly resolved solutions to the turbulent flow field. Spray modeling capabilities were implemented into the Nek5000 code. The spray is modeled in a Lagrangian–Eulerian (LE) framework, where the liquid is represented by discrete parcels of droplets. The method for coupling liquid and gas in the context of SEM is described, which allows for very fine meshes to be used without affecting the stability of the solution. Large-eddy simulations (LES) of the eight-hole ECN Spray G gasoline injector were conducted. Numerical results are compared against experimental data for liquid penetration, droplet size and gas velocity. The morphology of the multiplume spray is compared against experimental data. The effect of different spray injection inputs is analyzed. It was found that using a plume direction of 33 deg and an injection cone angle of 30 deg produced the best results overall. This work shows the applicability of SEM for spray modeling applications, where use of a high-order flow solver can help us understand the multiplume spray aerodynamics and how it leads to plume collapse under certain conditions. Results also highlight the need for tuning spray input parameters in the LE framework, even when high-fidelity gas flow solutions are possible.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Development of a Method for Shape Optimization for a Gas Turbine Fuel Injector Design Using Metal-Additive Manufacturing

Adjoint shape optimization has enabled physics-based optimal designs for aerodynamic surfaces. Additive manufacturing (AM) makes it possible to manufacture complex shapes. However, there has been a gap between optimal and manufacturable surfaces due to the inherent limitations of commercial computational fluid dynamics (CFD) codes to implement geometric constraints during adjoint computation. In such cases, the design sensitivities are exported and used to perform constrained shape modifications using parametric information stored in computer aided design (CAD) files to satisfy manufacturability constraints. However, modifying the design using adjoint methods in CFD solvers and performing constrained shape modification in CAD can lead to inconsistencies due to different shape parameterization schemes. This paper describes a method to enable the simultaneous optimization of the fluid domain and impose AM manufacturability constraints, resolving one of the key issues of geometry definition for isogeometric analysis. Similar to a grid convergence study, the proposed method verifies the consistencies between shape parameterization techniques present within commercial CAD and CFD software during mesh movement as a part of the adjoint shape optimization routine. By identifying the appropriate parameters essential to a shape optimization study, the error metric between the different parameterization techniques converges to demonstrate sufficient consistencies for justifiable exchange of data between CAD and CFD. For the identified shape optimization parameters, the error metric to measure the deviation between the two parameterization schemes lies within the AM laser-powder bed fusion (L-PBF) process tolerance. Additionally, comparison for subsequent objective function calculations between iterations of the optimization loop showed acceptable differences within 1% variation between the modified geometries obtained using the two parameterization schemes. This method provides justification for the use of multiphysics guided adjoint design sensitivities computed in CFD software to perform shape modifications in CAD to incorporate AM manufacturability constraints during the shape optimization loop such that optimal designs are also additively manufacturable.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Experimental Validation of a High-Temperature Test Facility for Future Additive Manufactured Supercritical Carbon Dioxide Turbine Testing

For next-generation power plants to achieve high cycle efficiencies consistent with the Department of Energy's 65% efficiency target, turbomachinery capable of operating within high-temperature power cycles must be demonstrated. Pairing additively manufactured superalloy turbines with the supercritical carbon dioxide (sCO 2 ) power cycle could enable turbine inlet temperatures approaching 1300 °C while providing flexibility in turbine cooling strategies. Development of test facilities to characterize and validate such systems is crucial. In this study, a turbine test facility capable of achieving inlet conditions of 800 °C, 11 MPa, and 0.43 kg/s while accommodating complex auxiliary cooling flow requirements has been designed and constructed to support future testing of a Haynes 282 additively manufactured 30 kW turbine-generator system with advanced cooling channels. This facility enables characterization of aerodynamic performance, leakage, and windage losses. Details of the facility's construction and operation are presented, along with experimental validation tests using an orifice as an expansion device in place of the turbine. These tests confirm that the facility can reach the required conditions, distinguish regions of achievable steady and pseudo-steady conditions, and identify the heater power required for each point in the upcoming turbine campaign. The campaign confirmed that ISO 5167-2 can reliably predict orifice mass flow rates in extreme supercritical carbon dioxide conditions with deviations of 0.5–7.5%.

42 ENGINEERING↗
DOE OSTI2023

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗
DOE OSTI2025

Experimental Analysis of Advanced Turbine for Supercritical CO2 Power Cycle

An advanced first stage high pressure turbine blade for a supercritical CO2 power cycle is tested in the Big Rig for Aerothermal Stationary Turbine Analysis (BRASTA) annular cascade at the Purdue Experimental Turbine Aerothermal Laboratory (PETAL) high pressure blow down facility alongside a baseline blade for comparison of aerodynamic performance. Both geometries are tested simultaneously using a novel off-axis rig design to allow for the blade geometries to be scaled up to achieve higher Reynolds numbers. The off-axis design necessitates the use of discrete sectors of airfoils, which are designed and additively manufactured in house using an mSLA printer. Printing the blades allows for unique routing of passage for blade surface static pressure taps that contour to the blade shape instead of requiring a straight line view from surface tap to egress, allowing all instrumentation for 15%, 50%, and 85% span to exist in the same passage. A flow conditioning gauze [1] is placed upstream of the blade passages to impart pressure, Mach, and swirl profiles to mimic the rotor relative frame inlet conditions to the blade. Downstream, a sonic valve is used to alter the backpressure to achieve different pressure ratios for different blowdown setpoints. The design of the rig, sonic wheel, and instrumentation are discussed along with the manufacturing and GD&T of the blades with respect to the build-up of this novel experimental apparatus. Initial commissioning data is obtained from inlet total pressure and temperature rakes, blade static pressure taps, and exit total pressure rakes. Oil visualization is performed using a silicone oil mixture containing titanium dioxide and pigmented for contrast of the blade suction side surface with the hub and shroud endwalls. The viscosity of the oil is tuned so that the oil does not fully thin and blow away during the time of the test, and endoscopic cameras are placed in the rig for live monitoring and recording. The preliminary oil visualization and rake profiles are presented, showcasing the operability of this additively manufactured off-axis flow path design.

Tuite, Logan [Purdue University]↗
DOE OSTI2021

Functional Requirements for the WEIS Toolset to Enable Controls Co-Design of Floating Offshore Wind Turbines

The goal of the new Wind Energy with Integrated Servo-control (WEIS) toolset under development is to provide the offshore wind industry and research communities with an open-source, user-friendly, flexible tool to enable true controls co-design (CCD) of the physical design of a floating offshore wind turbine together with the controller. WEIS will use a multifidelity library of models built on the foundations of WISDEM® and OpenFAST formerly known as FAST). This paper presents the WEIS development plan, including the functional requirements of WEIS (including improvements to WISDEM and OpenFAST) together with associated rationale for their establishment and a qualitative description of the modeling approaches that will be implemented to address these functional requirements. The development of WEIS is a project under the Aerodynamic Turbines Lighter and Afloat with Nautical Technologies and Integrated Servo-control program funded by the U.S. Department of Energy Advanced Research Projects Agency – Energy.

27 ARPA - Advanced Research Projects Agency-Energy↗
DOE OSTI2022

Fluid Dynamics of Axial Turbomachinery: Blade- and Stage-Level Simulations and Models

The current generation of axial turbomachines is the culmination of decades of experience, and detailed understanding of the underlying flow physics has been a key factor for achieving high efficiency and reliability. Driven by advances in numerical methods and relentless growth in computing power, computational fluid dynamics has increasingly provided insights into the rich fluid dynamics involved and how it relates to loss generation. This article presents some of the complex flow phenomena occurring in bladed components of gas turbines and illustrates how simulations have contributed to their understanding and the challenges they pose for modeling. The interaction of key aerodynamic features with deterministic unsteadiness, caused by multiple blade rows, and stochastic unsteadiness, i.e., turbulence, is discussed. High-fidelity simulations of increasingly realistic configurations and models improved with help of machine learning promise to further grow turbomachinery performance and reliability and, thus, help fluid mechanics research have a greater industrial impact.

Mechanics↗
DOE OSTI2023

Numerical Manufacturing And Design tool

NuMAD helps to enable efficient creation and use of high fidelity wind turbine blade models for structural and aerodynamic analysis. NuMAD is a GUI-based tool used to manage the specific geometry and materials inputs required to fully describe a wind turbine blade.

Berg, Jonathan↗
DOE OSTI2021

Code Artifact for: Clustering Analysis of Commercial Vehicles Using Automatically Extracted Features from Time Series Data [SWR-21-96]

This repository contains data ingestion, feature extraction, and analysis code used in NREL Technical report "Clustering Analysis of Commercial Vehicles Using Automatically Extracted Features from Time Series Data." The code is written in Python. The ETL and feature extraction code must be run in a Spark context. The analysis code can be run without Spark, provided you have pre-computed features in a CSV file. Analysis code related to the NREL Technical Report NREL/TP-2C00-74212. Includes PySpark functions to perform trip segmentation and feature extraction over big time series data in Apache Spark. Includes "domain specific" features such as Aerodynamic Speed (ft/s), Characteristic Acceleration (ft/s2), Percent Below 55 (%), Percent Zero (%), Stops Per Mile, Average Speed (mph), Maximum Speed (mph), and Speed Standard Deviation (mph). Includes Pyspark UDF to compute "domain agnostic" features using the TSFresh library. This software record also includes the analysis notebooks and code to generate the results in the previously mentioned technical report.

Perr-Sauer, Jordan↗
DOE OSTI2022

INN Airfoil Tools

This software package contains code to perform airfoil inverse shape design using a sparsified invertible neural network model. This is a specialized deep learning architecture that enables both network weights to be shared to evaluate forward or inverse passes through the network. As a design tool, this network allows practitioners to specify desired aerodynamic and structural properties and generate shapes that satisfy those properties. The invertible neural network is accompanied with tuned parameters as well as software tools to train new models as needed.

Glaws, Andrew↗
DOE OSTI2022

RAFT (Response Amplitudes of Floating Turbines) [SWR-22-40]

RAFT is a Python code for frequency-domain analysis of floating wind turbines. RAFT works in the frequency domain to provide efficient computations of a floating wind system's response spectra accounting for platform hydrodynamics, quasi-static mooring reactions, rotor aerodynamics, and linearized control. It can be used to calculate response amplitude operators (RAO's), power spectral densities, mean/static properties, and response metrics based on mean and root-mean-square values of each output. RAFT serves as the Level 1 model in the WEIS (Wind Energy with Integrated Servo-control) toolkit, and features an OpenMDAO wrapper.

Hall, Matthew↗
DOE OSTI2022

OpenTurbine [SWR-23-07]

OpenTurbine is an open-source code designed for the simulation of wind turbine structural dynamics. It is a flexible multi-body dynamics solver wherein the wind turbine is modeled as a collection of beam finite elements, rigid bodies, and constraints. OpenTurbine is equipped with an application programming interface primarily designed for coupling to computational fluid dynamics codes, but it is also suited for coupling to aerodynamics solvers based on blade element momentum theory.

Sprague, MichaelA.↗