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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

Carbon and Hydrocarbon Particle Seeding in Air-Breathing Rotating Detonation Engine

Within the power generation community, the rotating detonation engine (RDE) is only growing in popularity with its increased performance, simple mechanism, and operation. Although significant testing is underway to characterize the RDE for integration with conventional gas turbines, this entire system is still at a relatively low technology readiness level. In the midst of RDE research, there is an initiative to understand solid particle seeding effects in the detonation performance. Under investigation at the University of Central Florida is a Department of Energy (DOE) 15.24 cm (6 in.) RDE, with a solid particle seeder in parallel with its H2 and air flow lines. Previous work on this system involved carbon particle detonation; however, the tested particles were taken one step further to include more sustainable, greener hydrocarbon particles. Testing of powdered sugar, peanut flour, and cornstarch, along with previous carbon black tests have shown not only successful detonability, but a noticeable effect on the detonation wave dynamics. Side-by-side with a particle burning model being developed, an operational map can be determined for the hydrocarbon particles particularly, which can be tuned with the local flow conditions to achieve peak operability while replacing fuels with sustainable alternatives that could even be grown.

Engineering↗
DOE OSTI2021

Ultra-High Temperature Thermal Conductivity Measurements of a Reactive Magnesium Manganese Oxide Porous Bed Using a Transient Hot Wire Method

Pelletized magnesium manganese oxide shows promise for high temperature thermochemical energy storage. It can be thermally reduced in the temperature range between 1250 °C and 1500 °C and re-oxidized with air at typical gas-turbine inlet pressures (1–25 bar) in the temperature range between 600 °C and 1500 °C. The combined thermal and chemical volumetric energy density is approximately 2300 MJ/m3. The rate at which a thermochemical storage module can be charged is limited by heat transfer inside the solid packed bed. Hence, the effective thermal conductivity of packed beds of magnesium-manganese oxide pellets is a crucial parameter for engineering Mg-Mn-O redox storage devices. We have measured the effective thermal conductivity of a packed bed of 3.66 ± 0.516 mm sized magnesium manganese oxide (Mn to Mg molar ratio of 1:1) pellets in the temperature range of 300–1400 °C. Since the material is electrically conductive at temperatures above 600 °C, the sheathed transient hot wire method is used for measurements. Raw data is analyzed using the Blackwell solution to extract the bed thermal conductivity. The effective thermal conductivity standard deviation is less than 10% for a minimum of three repeat measurements at each temperature. Experimental results show an increase in the effective thermal conductivity with temperature from 0.50 W/m °C around 300 °C to 1.81 W/m °C close to 1400 °C. We propose a dual porosity model to express the effective thermal conductivity as a function of temperature. This model also considers the effect of radiation within the bed, as this is the dominant heat transfer mode at high temperatures. The proposed model accounts for microscale pellet porosity, macroscale bed porosity, pellet size, solid thermal conductivity (phonon transport), and radiation (photon transport). The coefficient of determination between the proposed model and the experimental results is greater than 0.90.

Engineering↗
DOE OSTI2021

Accelerated Creep Test Qualification of Creep-Resistance Using the Wilshire–Cano–Stewart Constitutive Model and Stepped Isostress Method

In this paper, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire–Cano–Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing is a long-term continuous process; in fact, the ASME B&PV III requires that 10,000+ h of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The SSM has been developed, which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750 °C and predictions are compared to conventional creep testing data. The WCS model has proven to make long-term predictions for stress-rupture, MCSR, creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are postaudit validated using the National Institute of Material Science database. Similarly, the MCSR predictions are compared from previous studies. Finally, the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and industrial gas turbines.

42 ENGINEERING↗
DOE OSTI2021

Energy demand reduction in the built environment using shallow geothermal integrated energy systems: Part II – Hybrid ground source heat pump for building heating

The research collection aims at finding the various possible opportunities for the effective integration of shallow geothermal energy (SGE) to decrease the energy demand in the built environment and to reduce emission associated with it. The direct utilization of SGE using a ground source heat pump (GSHP) has been reviewed in comprehensive review part I and part II. From the extensive review, we have found that the hybrid GSHP is needed to avoid ground thermal imbalance and peak demand. Hybrid GSHP can adopt various supplemental heat sources and sinks according to the local climatic conditions and the balance of energy demands. The primary focus on the integration of subsystems such as biomass, solar energy (PV, PVT, and collector), phase change material, micro gas turbine, and absorption heat pump with GSHP is presented for heating application. This comprehensive review part III highlights the recent research findings and a potential gap in hybrid GSHP for further research and developments

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Printability and Overall Cooling Performance of Additively Manufactured Holes With Inlet and Exit Rounding

Abstract To improve cooling effectiveness of gas turbine hardware, various film cooling hole shapes have previously been researched. Unique design modifications have recently been made possible through the design freedom allotted by additive manufacturing (AM). As one example, creating a rounded inlet for a film-cooling hole can mitigate separation at the inlet. This study explores various geometric features by exploiting the uses of additive manufacturing for shaped film cooling holes at engine scale. Both printability and cooling performance were evaluated. Resulting from this study, additively manufactured holes with hole inlet and exit rounding were printed with some variations from the design intent (DI). The largest deviations from the design intent occurred from dross roughness features located on the leeward side of the hole inlet. The measured overall effectiveness indicated that an as-built inlet fillet decreased in-hole convection as well as decreased jet mixing compared to the as-built sharp inlet. Including an exit fillet, which prevented an overbuilt diffuser exit, was also found to decrease jet mixing. A particular insight gained from this study is the importance of the convective cooling within the hole to the overall cooling performance. In-hole roughness, which is a result of additive manufacturing, increased convective cooling within the holes but also increased jet mixing as the coolant exited the hole. The increased jet mixing caused low overall effectiveness downstream of injection.

Engineering↗
DOE OSTI2023

Heat Transfer and Pressure Loss of Additively Manufactured Internal Cooling Channels With Various Shapes

Abstract Additive manufacturing (AM) provides the ability to fabricate highly customized internal cooling passages that are relevant to gas turbine components. This experimental study examines the pressure loss and heat transfer performance of a range of fundamental channel shapes that were produced using direct metal laser sintering. Circular, hexagonal, pentagonal, elliptical, diamond, square, rectangular, trapezoidal, and triangular channel cross sections were investigated. To maintain the same convective surface area between shapes, the wetted perimeters of the channel cross sections were kept constant. Parallel computational fluid dynamic simulations were performed to understand the relationships in cooling performance between several channel shapes. Several characteristic length scales were evaluated to scale the pressure loss and heat transfer measurements. Among the channel shapes investigated, the diamond channel showed the lowest Nusselt number and friction factor. The pentagon exhibited a similar Nusselt number as the circular channel despite having a lower friction factor. There was no difference in scaling the friction factor or Nusselt number results of the different channel shapes between using the square root of cross-sectional area compared to hydraulic diameter as the characteristic length scale

Engineering↗
DOE OSTI2023

The Effects of Channel Supplies on Overall Film-Cooling Effectiveness

Abstract Cooling components in the hot section of a gas turbine are essential to component durability. Common methods of cooling include rib turbulators in internal passages and film cooling on external surfaces. The holes that produce the film cooling are fed from the internal channels often containing ribs. Consequently, there is an interdependence of internal heat transfer and external film cooling. The purpose of this study was to obtain a better understanding of the interaction of ribs and film cooling. To quantify the cooling performance, the surface temperatures were measured, from which overall effectiveness was calculated. For the experiments, additively manufactured test coupons were made of Inconel 718 to match engine Biot numbers. These test coupons had internal feed channels with and without ribs and had both cylindrical holes and meter-diffuser-shaped holes with 15 deg lateral expansion angles and a 1 deg forward expansion angle. A single rectangular channel was one type of feed channel. The other type of feed channel was individual circular channels, with each circular channel supplying an individual film-cooling hole. The experimental results showed that the circular individual channels have 80% higher baseline overall effectiveness than the single rectangular channels without any film cooling. Ribbed turbulators without film cooling also increased the overall effectiveness by 21% for single rectangular channels and by 29% for the circular individual channels compared to the respective non-ribbed channels. While the film cooling increased the overall effectiveness of all geometries, the single rectangular channels had increased overall effectiveness levels by up to twice that of the no film-cooling case. On average, the single rectangular channels had an 80% improvement from film cooling, whereas the individual channel feeds, on average, had only a 50% improvement, given their high baseline effectiveness levels.

Engineering↗
DOE OSTI2024

Impacts of Superalloys on the Surface Quality of Additively Manufactured Channels

Abstract Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high-temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM), with one superalloy based on cobalt and the other on nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion machines. Several build conditions were varied between coupon sets, including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were computed tomography (CT) scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had a significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases, the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.

Engineering↗
DOE OSTI2024

Overall Cooling Effectiveness With Internal Serpentine Channels and Optimized Film Cooling Holes

Abstract The overall cooling effectiveness for gas turbine airfoils is a function of the combined cooling due to internal cooling configurations and film cooling configurations. Typically, film cooling configurations are evaluated independent of the cooling effects of the internal feed channels, generally based on adiabatic effectiveness measurements. In this study, we consider the coupled effects of internal cooling and film cooling configurations through measurements of overall cooling effectiveness for film cooling holes fed by a coflow/counterflow channel and a serpentine channel. A film cooling hole designed by adjoint optimization techniques (X-AOpt) is compared to a standard-shaped hole with 7 deg forward and lateral expansions (7-7-7 SI). Experiments without film cooling showed that the serpentine channel had 35–50% greater overall cooling effectiveness than the straight, coflow channel. Experiments with the X-AOpt hole combined with a serpentine channel showed an area-averaged overall cooling effectiveness of ϕ¯¯=0.58, which was a 70% increase compared to the overall cooling effectiveness of the serpentine channel without film cooling. When the X-AOpt hole was fed with a coflow channel with similar coolant mass flowrate, the overall cooling effectiveness was ϕ¯¯=0.44, i.e., 30% lower than when using the serpentine channel. Interestingly, adiabatic effectiveness measurements with the X-AOpt holes showed a more uniform hole-to-hole performance when using the serpentine channel compared to the coflow channel.

Engineering↗
DOE OSTI2025

Simplified Model and Approach to Transform Infrared Surface Temperature to Film Effectiveness in a Conjugate Heat Transfer Experiment

In the pursuit of more efficient gas turbines, film cooling is a critical technology. This article describes a simplified engineering model based on a one-dimensional thermal resistance network. The model is used to relate film-cooling effectiveness and heat transfer augmentation to local overall cooling effectiveness in a conjugate flat plate experiment. Here, this article presents experimental proof-of-concept data to demonstrate the potential for this model. In contrast to previous approaches, neither the wall heat flux nor the adiabatic wall temperature is required to estimate the local film-cooling performance parameters. The model predicts surface temperatures that are within the experimental uncertainties over the range for which the model is trained and to within five percent when the model is extrapolated to higher coolant channel Reynolds numbers. This article is relevant to conjugate test rigs that can measure the hot-surface temperature distribution with and without film cooling. This information may also be relevant to designers as a method to approximate surface temperatures or used as an approximate heat transfer model for optimization studies.

advanced turbines↗
DOE OSTI2021

Data Driven Fault Detection of Premixer Centerbody Degradation in a Swirl Combustor

This paper introduces a data-driven framework for combustor-focused, performance-based condition monitoring of gas turbines. Commercial condition monitoring systems typically generate huge amounts of data that make efficient onboard monitoring challenging. This paper focuses on quantifying combustor component degradation, using premixer centerbody degradation in a swirl stabilized combustor as a case study. The input for these analyses is acoustic pressure measurements acquired at various locations on the combustor. The diagnosis methodology is based on a classification framework and consists of 3 steps: 1) Data curation, 2) Feature Engineering, and 3) Diagnosis. Data curation ensures good quality of the data that is passed through the algorithm. Feature engineering deals with the extraction of the most informative features, from the most informative sensors, that can accurately capture the introduced fault. To perform diagnosis, the classification model is trained using experimentally acquired data and is then tested on a separate data set. The framework was able to achieve high classification accuracy (>99%) for training size as low as 30% of the total recorded observations. The low number of features required to achieve this accuracy suggests high potential for integration into existing onboard condition monitoring systems.

data driven methods, fault detection, swirl flames↗
DOE OSTI2021

Identification of High-Frequency Transverse Acoustic Modes in Multi-Nozzle Can Combustors

Abstract High frequency thermoacoustic instabilities are problematic for lean-premixed gas turbines. Identifying which acoustic mode is being excited is important, in that it provides insight into potential mitigation measures and mechanical stress/life. However, the frequency spacing between modes becomes quite close for high frequency instabilities in a can combustor. This makes it difficult to distinguish between the modes (e.g., the first transverse mode vs. a higher order axial/mixed mode) based upon frequency calculations alone, which inevitably have uncertainties in boundary conditions, temperature profiles, and combustion response. This paper presents a methodology to simultaneously identify the acoustic mode shapes in the axial and azimuthal directions from acoustic pressure measurements. Multiple high temperature pressure transducers, located at distinct axial and azimuthal positions, are flush mounted in the combustor wall. The measured pressure oscillations from each sensor are then used to reconstruct the pressure distributions by using a least squares method in conjunction with a solution of a three dimensional wave equation. In order to validate the methodology, finite element method (FEM) calculations with estimated post-flame temperature is used to provide the candidate frequencies and corresponding mode shapes. The results demonstrate the reconstructed mode shapes and standing/spinning character of transverse waves, as well as the associated frequencies, both of which are consistent with the FEM predictions. Nodal line location was also extracted from the experimental data during the instabilities in the pressure data.

Kim, J.↗
DOE OSTI2023

Flashback of Hydrogen-Methane Mixtures in a Fixed-Vane, Low-Swirl Burner at Atmospheric Pressure

Equivalence ratio at flashback, 𝜙FB, of low swirl injectors for 60% – 95% (H2, by mole) hydrogen-methane mixtures was determined experimentally in a < 100 kW atmospheric pressure burner. Pre-mixer velocities equaled 5, 7.5, and 10 m/s, with the reactants entering the burner at 294 K. The swirler design was selected following a literature review, and the test articles were additively manufactured. The test articles had two turning angles, 26° and 33°, with center-body hole diameters equaling 1.08 and 1.16 mm. A test article was built with each parameter combination, which yielded four test articles with measured swirl numbers varying from 0.43 to 0.49. The results showed agreement with prior work. 𝜙FB increased with increasing pre-mixer velocity and decreasing percent hydrogen. 𝜙FB was also observed to increase with swirl angle and decrease with increasing center-body hole diameter. The data was correlated using a semi-empirical quenching approach, with 𝐶quench=0.01, where the chemical time scale was calculated using a perfectly stirred reactor (PSR) model. Two different chemical kinetics mechanisms independently yielded the same results. The correlation makes the present small-scale laboratory results relevant to large, high-pressure gas turbines. The flashback data set is available for computational fluid dynamics (CFD) validation.

Searle, Matthew↗
DOE OSTI2025

Micromechanical Surrogate Machine Learning Model for Creep Deformation Modeling

Process variability during the manufacture of gas turbine engine hot section components can significantly affect the material’s resulting microstructure. In casting, for instance, geometric variation within a component (thin sections versus thick sections, radial location) influences cooling rates and the resulting grain size. The high temperature creep response is known to be sensitive to grain size owing to a diffusional creep mechanism which occurs more readily along grain boundaries. Microstructural variation correspondingly drives mechanical behavior which propagates into component scale performance uncertainty. These factors are essential when planning inspection, maintenance, and repair strategies within a reliability framework. These benefits provide opportunities to increase overall energy efficiency through refined margins. Critically, there is an opportunity to bolster existing data-driven reliability models using physics-driven process-structure-property relations. Here we present recent work establishing a framework for evaluating the probabilistic creep performance of high-temperature materials. A novel microstructure-sensitive crystal plasticity finite element model is established that captures both grain boundary and crystallographic deformation effects. The computationally expensive physics model is calibrated using a statistical approach and this high-fidelity model is subsequently used to train a computationally efficient machine learning surrogate model. The surrogate model is essential for sampling a large ensemble of simulated structure-property pair results. The ensemble data are then mined to extract salient trends to be incorporated into a microstructure-sensitive reliability model. The proposed approach represents a novel way to capture microstructure-sensitive trends from physics-based models within a modern reliability framework.

Fernandez-Zelaia, Patxi [ORNL]↗
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 OSTI2021

Hybrid Simulation Framework

HYBRID is a modeling toolset to assess the economic viability of Nuclear-Renewable Integrated Energy Systems (N-R IES). The frameworks enabling this toolset are INL’s RAVEN, its CashFlow plugin and the Modelica language. The toolset includes sample RAVEN workflows performing economic assessments. These workflows consist of: generation of stochastic time series and application of probabilistic analysis and optimization algorithms (RAVEN); a library of Modelica models representing the physical behavior of N-R IES; and the CashFlow plugin mapping physical performance to economic performance. The toolset allows assembling existing and new models such as nuclear reactors, renewable energy sources, energy storage, gas turbines, industrial processes, etc. into an N-R IES. The toolset workflows evaluate the dynamics of the N-R IES responding to stochastic conditions (electricity demand, price, etc.) and optimize the dispatch economics as well as N-R IES capacity planning.

Epiney, Aaron↗
DOE OSTI2022

PeleLMeX [SWR-22-48]

PeleLMeX is a solver for high fidelity reactive flow simulations, namely direct numerical simulation (DNS) and large eddy simulation (LES). The solver combines a low Mach number approach, adaptive mesh refinement (AMR), embedded boundary (EB) geometry treatment and high performance computing (HPC) to provide a flexible tool to address research questions on platforms ranging from small workstations to the world's largest GPU-accelerated supercomputers. PeleLMeX has been used to study complex flame/turbulence interactions in RCCI engines and hydrogen combustion or the effect of sustainable aviation fuel on gas turbine combustion. PeleLMeX is part of the Pele combustion Suite (https://amrex-combustion.github.io/)

Day, Marcus↗
DOE OSTI2022

Task Information Presentation System

Demonstrate a novel computer-based procedure solution for a multi-unit power plant. TIPS is developed to demonstrate a way to operate a highly automated plant. Currently, there are no plants (nuclear or non-nuclear) that can support this high level of automation. The purpose of TIPS is to help the industries think beyond the current conduct of operations. TIPS is designed to work with the GSE Systems' Combine-cycle gas turbine power plant simulator. TIPS uses the plant data from the simulator to make the user experience of the computer-based procedure more realistic.

Oxstrand, Johanna↗