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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Validation of the HyRAM+ physics models for use with propane

The Hydrogen Risk Assessment Model Plus (HyRAM+) toolkit combines quantitative risk assessment with simulations of unignited dispersion, ignited turbulent diffusion flames, and indoor accumulation with delayed ignition of fuels. HyRAM+ is differentiated from HyRAM in that it includes models and leak data for other alternate fuels. The models of the physical phenomena need to be validated for each of the fuels in the toolkit. This report shows the validation for propane which is being used as a surrogate for autogas, which is a mixture of propane and butane and used in internal combustion engines in vehicles. For flame length comparisons, five previously published experiments from peer reviewed journals were used to validate our models. The validation looked at flame lengths and flame widths with respect to different leak diameters, mass flow rates, and source pressures. Most of the sources included more than one set of experimental data, which were collected using different methods (CCD cameras, IR visualization etc.). In general, HyRAM+ overpredicts the flame lengths by around 65%. For heat and radiation models, we compared the heat flux and radiation data reported from two different sources to the values calculated by HyRAM+. For higher mass flow rates, the HyRAM+ calculated flame length results gave a better estimate of what is found in the experiments (65% error), but a higher error (85%) is observed between the HyRAM+ calculated lengths and the experimental flame lengthsfor lower mass flows. Some differences can be attributed to outdoor environmental effects (i.e. wind speed) and uncertainties in jet flame shapes. The propane flame trajectory is predicted for a high Reynolds number case with Re = 12,500 and a low Reynolds number case where Re = 2,000. The Re=12,500 case which is momentum dominated matches well with the experimental flame trajectory, but the agreement for the bouancy driven low Reynolds number case is not as good. Dispersion modeling for unignited propane was also analyzed. We compared the mole fraction, mixture fraction, mean velocity, concentration half width, and inverse mass concentration over an axial distance from different credible journals to the values calculated by HyRAM+. The results display good agreement but generally, HyRAM+ predicts a wider profile for mole fraction and mixture fraction experiments. Overall, HyRAM+’s results are reasonable for predicting the flame length, heat flux, flame trajectory, and dispersion for propane and can be used in risk analyses

08 HYDROGEN↗
DOE OSTI2021

Effect of process route on powder three-dimensional-printing of metal powders

The purpose of this study is to investigate the effect of two unique processing routes (solvent jetting (SJ) and binder jetting (BJ)), on the green density of printed stainless steel 316L (SS316L) and Nickel (Ni) powders. In the SJ processing route, a solvent is jetted unto the powder/binder mixture to selectively activate the binder, layer by layer. In the BJ processing route, a solution of the binder mixture is jetted onto the powder bed to selectively bind powder particles. The effects of printing parameters such as layer height, roller speed, shaker speed and nozzle temperature on the green density of printed components are investigated and compared for both processing routes. Results show that layer height and nozzle temperature affect the relative density of the printed compact for both processing routes. Slightly higher relative densities were achieved via the SJ route, with the overall highest relative density being 42.7% at 100 µ m layer height and 70% nozzle temperature for the SS316L components and 43.7% at 150 µ m layer height and 90% nozzle temperature for the Ni components, respectively. Results also show an increase in the final sintered relative density with an increase in green (printed) relative density of the solvent jetted SS316L components, with the highest relative density being 87.2%. The paper studies the influence of printing parameters on the green density of printed SS316L and Ni samples in an unprecedented effort to provide a comparative understanding of the process-property relationships in BJ and SJ of SS316L and Ni components to the additive manufacturing research community.

Engineering↗
DOE OSTI2021

Using Particle Image Velocimetry to Determine Turbulence Model Parameters

The primary parameter of a standard k-ϵ model, C μ , was calculated from stereoscopic particle image velocimetry (PIV) data for a supersonic jet exhausting into a transonic crossflow. This required the determination of turbulent kinetic energy, turbulent eddy viscosity, and turbulent energy dissipation rate. Image interrogation was optimized, with different procedures used for mean strain rates and Reynolds stresses, to produce useful turbulent eddy viscosity fields. The eddy viscosity was calculated by a least-squares fit to all components of the three-dimensional strain-rate tensor that were available from the PIV data. This eliminated artifacts and noise observed when using a single strain component. Local dissipation rates were determined via Kolmogorov’s similarity hypotheses and the second-order structure function. The eddy viscosity and dissipation rates were then combined to determine C μ . Considerable spatial variation was observed in C μ , with the highest values found in regions where turbulent kinetic energy was relatively low but where turbulent mixing was important, e.g., along the high-strain jet edges and in the wake region. This suggests that use of a constant C μ in modeling may lead to poor Reynolds stress predictions at mixing interfaces. A data-driven modeling approach that can predict this spatial variation of C μ based on known state variables may lead to improved simulation results without the need for calibration.

42 ENGINEERING↗
DOE OSTI2020

Ultracompact 3D microfluidics for time-resolved structural biology

To advance microfluidic integration, we present the use of two-photon additive manufacturing to fold 2D channel layouts into compact free-form 3D fluidic circuits with nanometer precision. We demonstrate this technique by tailoring microfluidic nozzles and mixers for time-resolved structural biology at X-ray free-electron lasers (XFELs). We achieve submicron jets with speeds exceeding 160 ms -1 , which allows for the use of megahertz XFEL repetition rates. By integrating an additional orifice, we implement a low consumption flow-focusing nozzle, which is validated by solving a hemoglobin structure. Also, aberration-free in operando X-ray microtomography is introduced to study efficient equivolumetric millisecond mixing in channels with 3D features integrated into the nozzle. Such devices can be printed in minutes by locally adjusting print resolution during fabrication. This technology has the potential to permit ultracompact devices and performance improvements through 3D flow optimization in all fields of microfluidic engineering.

3-D reconstruction↗
DOE OSTI2020

Report on Progress of correlation of in-situ and ex-situ data and the use of artificial intelligence to predict defects

The Transformational Challenge Reactor (TCR) program is leveraging additive manufacturing (AM) technologies to fabricate nuclear components which will be assembled into a fully functional microreactor core. Compared with traditional manufacturing technologies, AM technologies allow (1) real-time observation of the manufacturing process at a much higher resolution using in-situ monitoring technologies to capture the sensor signatures that scientifically describe each event occurring over time and space and (2) validation of the manufacturing process quality using domain-informed data analytics techniques as a potential qualification and certification methodology for the final component. This report provides an update on the program work on in-situ and ex-situ data correlation and associated data analytics results. Examples are provided to illustrate progress with respect to laser powder bed fusion (L-PBF), binder jetting, computed tomography (CT) reconstruction, and mechanical testing. Elements of the Digital Thread and data management infrastructure are discussed in the main document, and an extensive supplemental appendix is provided detailing the Digital Platform, as well as its implementation and subcomponents. In conclusion, the path forward for the next fiscal year is also discussed.

42 ENGINEERING↗
DOE OSTI2022

Measuring Critical Fuel Properties for Simulations to Accelerate Fuel Qualification

NREL's sustainable aviation fuel (SAF) research in the area of fuel properties and end use is focused on accelerating SAF development and deployment. This will be achieved by close collaboration with BETO program researchers on fuel property measurement and development of structure-property relationships. Additionally, fuel properties measured at often extreme engine operating conditions will be measured, and will be used as inputs to exascale ready simulations of aviation combustion turbines to reveal impacts of properties on turbine operation. This research will potentially lead to a widening of the allowable fuel property range for SAF, expanding SAF production process options and production volumes.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Laser diagnostics to characterize the in-flame growth of platinum nanoparticles manufactured by the reactive spray deposition technology

Reactive Spray Deposition Technology (RSDT) is an atmospheric pressure, flame-based advanced manufacturing method used to fabricate Membrane Electrode Assemblies (MEAs) for proton exchange fuel cells and water electrolyzers. RSDT combines the flame synthesis of catalyst nanoparticles and their deposition onto the membrane in one step. The properties of the synthesized nanoparticles, such as their Size Distribution Function (SDF), determine the manufactured electrodes’ performance, which can be evaluated when the deposition is complete via ex-situ characterization of the products. Efforts to improve RSDT for manufacturing state-of-the-art MEAs can be significantly enhanced with integrated laser diagnostics that enable in situ measurement of the synthesized catalyst nanoparticles. This paper reports the implementation of laser diagnostics in an RSDT facility and evaluates their potential to assist the manufacturing process. Laser Light Scattering (LS) and Laser-Induced Incandescence (LII) measurements are performed in the oxygen-rich zone of the flame at various distances from the flame fuel jet nozzle downstream of its luminous region. The measurements quantitatively track the evolution in size and volume fraction of platinum-based nanoparticles in two flames that yield different catalytic properties in the manufactured electrodes. The profiles of the measured nanoparticles’ volume fraction along the flame axis can be estimated a priori so that the average nanoparticle sizes can be measured in quasi-real time via LS. Nanoparticles experience an extremely slow growth rate while being convected at distances from 150 nm to 300 nm from the fuel nozzle. Complementary characterizations of the synthesized nanoparticles are performed ex-situ via High-Angle Annular Darkfield Scanning Transmission Electron Microscopy (HAADF-STEM) image analyses of samples collected on grids at a fixed distance from the fuel jet nozzle. Comparing the results from laser and microscopy techniques not only cross-validates the findings but also provides the parameters to infer the bimodal SDF in-situ and yields evidence that the coagulation efficiency of the synthesized nanoparticles has extremely low values in the investigated zone of the flames.

Rayleigh Light Scattering (LS)↗
DOE OSTI2023

Strongly Heated Turbulent Flow in a Channel with Pin Fins

Large-eddy simulations (LES) were performed to study the turbulent flow in a channel of height H with a staggered array of pin fins with diameter D = H/2 as a function of heating loads that are relevant to the cooling of turbine blades and vanes. The following three heating loads were investigated—wall-to-coolant temperatures of Tw/Tc = 1.01, 2.0, and 4.0 - where the Reynolds number at the channel inlet was 10,000 and the back pressure at the channel outlet was 1 bar. For the LES, two different subgrid-scale models—the dynamic kinetic energy model (DKEM) and the wall-adapting local eddy-viscosity model (WALE)—were examined and compared. This study was validated by comparing with data from direct numerical simulation and experimental measurements. The results obtained show high heating loads to create wall jets next to all heated surfaces that significantly alter the structure of the turbulent flow. Results generated on effects of heat loads on the mean and fluctuating components of velocity and temperature, turbulent kinetic energy, the anisotropy of the Reynolds stresses, and velocity-temperature correlations can be used to improve existing RANS models.

42 ENGINEERING↗
DOE OSTI2024

Reducing Richtmyer–Meshkov instability jet velocity via inverse design

In this work, we detail a novel application of inverse design and advanced manufacturing to rapidly develop and experimentally validate modifications to a shaped charge jet analog. The shaped charge jet analog comprises a copper liner, a high explosive (HE), and a silicone buffer. Here, we apply a genetic algorithm to determine an optimal buffer design that can be placed between the liner and the HE that results in the largest possible change in jet velocity. The use of a genetic algorithm allows for discoveries of unintuitive, complex, yet optimal buffer designs. Experiments using the optimal design verified the effectiveness of the buffer and validated the machine learning approach to hydrodynamic design optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2022

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗
DOE OSTI2021

Genetically engineered oleaginous yeast Lipomyces starkeyi for sesquiterpene a-zingiberene production

In this study we demonstrate that transgenic Lipomyces starkeyi strains expressing a ?-zingiberene synthase gene from Lemon basil or Hall’s panicgrass can produce up to 17 mg/l of ?-zingiberene in yeast extract peptone dextrose (YPD) medium containing 4% glucose. Following these findings, the transgenic strain was examined in 8% glucose media with C/N ratios of 20 or 80, and YPD. YPD medium resulted in 59.2 mg/l??-zingiberene accumulation. We further improved ?-zingiberene production by over-expression of selected genes from mevalonate pathway and achieved 145% improvement in ?-zingiberene synthesis. The growth medium was optimized for ?-zingiberene production, which resulted in 14.9% higher titer than YPD medium. The final transgenic strain produced 700 mg/l ?-zingiberene in fed-batch bioreactor culture. This study opens a new synthetic route to produce ?-zingiberene or other terpenoids in the oleaginous yeast L. starkeyi and establishes this yeast as a platform for jet fuel biosynthesis.

Dai, Ziyu↗
DOE OSTI2021

Millimeter-wave electromagnetic monitoring for liquid metal droplet-on-demand printing

As new printing approaches emerge, in situ diagnostics to monitor the print quality in real-time become essential for long-term monitoring and feedback control. In this article, we present a millimeter-wave electromagnetic monitoring approach for liquid metal droplet-on-demand printing to support the high-speed and real-time evaluation of droplet ejection. An open-ended rectangular waveguide is placed perpendicular to a jetted droplet stream and operated at a continuous-wave frequency of 40 GHz. Liquid metal droplets with diameters as low as 1.2 mm are characterized, and droplet jetting events on the order of 500 μm are detected at ejection rates up to 80 Hz. The measured results demonstrate that trends at the macro-level (large-scale print variation and anomalies at the nozzle tip) as well as micro-level (droplet size, position, and dynamics) can be detected using this technique.

42 ENGINEERING↗
DOE OSTI2025

Machine Learning Analysis of Temperature-Strain Relationships for Structural Health Monitoring of Pipes: Self-powered wireless sensor system for health monitoring of liquid-sodium cooled fast reactors

This report presents machine learning (ML) analysis of temperature-strain relationships for structural health monitoring of nuclear reactor stainless steel (SS) pipes with the strain gauge sensor directly printed on the pipe with a 3D conformal aerosol jet printer. We investigate correlations for two sensor pairs installed on the same SS304 pipe: commercial K-type thermocouple with a printed gold strain gauge (TC3-SG3), and commercial K-type thermocouple with commercial Kyowa strain gauge (TC0-SG0). The temperature ranges for the sensor pairs TC0-SG0 and TC3-SG3 are 20.00°C to 266.37°C and 39.95°C to 219.28°C respectively. ML algorithms in this study include Linear Regression (baseline method), Ridge Regression, Lasso Regression, and Gradient Boosting. Performance evaluation metrics include Root Mean Square Error (RMSE), Mean Square Error (MSE), Mean Absolute Error (MAE), R 2 Score, and Explained Variance. Using advanced feature engineering techniques, we extracted 27 temperature-based features and 30 strategic inclusion features. The best performance was obtained with the Gradient Boosting method, which achieves prediction accuracy of R 2 = 0.9999 and RMSE = 7.69 μStrain for TC0-SG0, and R 2 = 0.9998 and RMSE = 18.03 μStrain for TC3-SG3. While the temperature-strain correlations are weaker for the gauge directly printed on the pipe than for the commercial strain gauge, deployment-ready performance exceeding industry standards is achieved for both sensor pairs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Technology Demonstration of a High-Pressure Swirl Oxy-Coal Combustor

This technical report presents the exploration of the design and prototyping of a High-Pressure Swirl Oxy-coal Combustor. Pressurized oxy-coal combustion systems have the potential to improve efficiency along with an increased carbon capture rate. Reduction of flue gas at higher pressure, smaller system size, and capital cost reductions render high-pressure oxy-coal systems particularly attractive as next-generation energy-producing systems. High-pressure oxy-coal combustion systems are a recent concept, and thus operability issues of combustor designs for such systems are not fully understood. Significant challenges exist to maintain oxy-coal combustion stability at elevated pressure and a high CO 2 diluent environment. Although a body of knowledge exists for high-pressure oxygen combustion in rocket engines (or similar applications), it is yet to be strategized how these fundamental concepts can be translated to low-temperature CO 2 diluent combustion regimes. The realization of the pressurized oxy-coal based systems requires combustor components to be designed and demonstrated for an operating pressure over 10 bar. However, pressurized oxy-coal combustor design information at this pressure range and scale relevant to validate those proposed systems is currently limited. Experimental data from MWth scale oxy-coal combustors are needed to identify the optimal trade-off between net efficiency and systems size. The proposed effort is aimed at demonstrating a 1 MWth down-fired swirl Oxy-Coal combustor and investigate the interrelation between combustor operating conditions (pressure; flame stability; flue gas recirculation ratio) and conversion efficiencies to minimize oxygen requirements. One of the key challenges is to configure burner design (i.e., swirl number and injector) and operating conditions for high-pressure oxy-coal combustion systems. These experiments differ from current systems partly due to the high theoretical flame temperature and related burner operability issues associated with oxy-combustion. An ASPEN PLUS® model study for 550 MWe TIPS and ENEL pressurized oxy-coal systems with CO 2 recirculation was performed to evaluate system design, subsystems sizing, and operating condition determination. The system analysis effort included TRL and technology gap determination of subsystems and critical components. This information was scaled to develop design requirements (design pressure and flue gas recirculation: RR Flue Gas = $\frac{m_{flue}}{m_{total}}$) for the 1 MWth combustor. The effects of a wide range of carbon dioxide recirculation ratios on the thermal efficiency of ENEL and TIPS cycles are studied. The pressure of 10 bar and 80 bar are used for ENEL and TIPS cycles, respectively. The thermal efficiency of ENEL is significantly higher than the efficiency of TIPS at a pressure of less than 10 bar. The insights from system analysis were then used to design a 1 MWth swirl oxy-coal combustor. Flame temperature analysis and material strength analysis was performed to determine the combustor thickness. The structural integrity of the combustor was validated by finite element analysis using Abacus® and Hypermesh®. Feasibility of igniters and secondary burners are investigated in successful high-pressure oxy-methane combustion. The secondary burners are designed in such a way that it can operate between 100 to 500 kW firing input. Three generations of the pintle injector were designed based on swirl numbers (S=0, 0.9, and 1.2). Key pintle injector parameters such as pintle size, pintle orifice size, spray pattern were investigated by cold flow tests. Information from these tests was used to modify injector design for smooth and successful operation. A 5 mm pintle orifice size was decided upon as the optimum size for oxy-coal operation for the combustor. Shadow sizing experiments were performed to identify the atomization rate of each injector. Different coal water slurry mixtures (30 – 50% coal by wt% in the mixture) at various total momentum ratios (TMR) were investigated for this purpose. These experiments provided decisive information to choose the best design of the injector. The injector with 1.2 swirl provided higher atomization in all cases than other designs. The mean equivalent droplet size of the jet was similar at different TMR and mixture ratios using this injector, thus making it suitable for use in most cases. Therefore, the 1.2 swirl-pintle injector was chosen for the shakedown test. The combustor and other sub-systems, including feed systems and control and data acquisition, have been manufactured, assembled, and integrated. The total system integration and installation began on July 1, 2020. The shake-down tests and initial operational capability demonstration are expected to be completed by September 30, 2020.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

High temperature additive manufacturing print head

A system of 3D printing using a high temperature 3D print head that functions as a “modified ink jet” printer. The print head has the ability to print high temperature material such as metal, silicon carbide, and other high temperature material as opposed to inks or plastics. The print head is fabricated from a high temperature material to maintain structural integrity while operation at temperatures above the melting temperature for the material that is being printed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High-speed volumetric imaging of formaldehyde in a lifted turbulent jet flame using an acousto-optic deflector

The development of high-speed volumetric laser-induced fluorescence measurements of formaldehyde (CH 2 O-LIF) using a pulse-burst laser operated at a repetition rate of 100 kHz is presented here. A novel laser scanning system employing an acousto-optic deflector (AOD) enables quasi-4D CH 2 O-LIF imaging at a scan frequency of 10 kHz. The diagnostic capability of time-resolved volumetric imaging is demonstrated in a partially premixed DME/air lifted turbulent jet flame near the flame base. Simultaneous imaging of laser beam profiles is performed to account for the laser pulse energy fluctuation and laser sheet inhomogeneity. With the accurate registration of laser sheet positions, the volumetric reconstruction of CH 2 O-LIF signals is performed within a detection volume of 17.3 × 11.9 × 2.3 mm 3 with an average out-of-plane spatial resolution of 250μm. A surface detection algorithm with adaptive thresholding is used to determine the global maximum intensity gradient by calculating gradient percentiles. The flame topology characteristics are investigated by evaluating the 3D curvatures of CH 2 O surfaces. Curvatures calculated using 2D data systematically underestimate the full 3D curvature due to the lack of out-of-plane information. The inner surfaces near the turbulent fuel jet exhibit higher probabilities of large mean curvature than the outer surfaces. The saddle and cylindrical structures are dominant on both the inner and outer surfaces and the elliptic structures occur with lower probability. The results suggest that the damping of turbulent fluctuations by the temperature increase through the CH 2 O region reduces the curvature, but the local structure topology remains self-similar.

42 ENGINEERING↗
DOE OSTI2023

Statement of Work: Toward AI-driven additive manufacturing for metal-ceramic composite structures

The project scope is to investigate the compatibility of various ceramic and metal powder composite feedstock development, implement AI algorithms for in-situ monitoring and parameter optimization of binder jet 3D printing to achieve reliable and robust metal/ceramic and/or ceramic/ceramic composite components, and create a generative design framework for heterogeneous composite structures incorporating metals and ceramic-based materials to achieve specific mechanical properties. Funded is the effort and travel by the faculty advisor at University of California Berkeley in support of the work of their students and the related collaborative research and development effort.

33 ADVANCED PROPULSION SYSTEMS↗