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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 37 records · Page 2

Preliminary Tuft Testing of Metallic Bristles Versus PS212, PS300, and HVOF300

Turbine engine brush seals are designed with sacrificial brushes and hard shaft coatings to minimize shaft wear and reduce the cost of engine overhauls. Replacing a worm seal is more cost and time effective than refinishing an engine shaft. However, this tribological design causes excessive brush wear and reduces long term seal efficiency. An alternative approach is to coat the shaft with a solid lubricant and allow the bristles to wear into the shaft coating similar to traditional abradable labyrinth seals. This approach can result in reduced seal leakage by forcing the leakage to flow through the seal bristle pack or through a more tortuous shaft wear track. Key to this approach is limiting the shaft wear to an acceptable level were surface refinishing would not be required during every engine overhaul. Included in this paper are brush seal tuft test results for four metallic bristles (nickel-chrome or cobalt-chrome based superalloys) tested against three solid lubricant coatings (NASA's PS212, PS300, and HVOF300). These test results are also compared to previous baseline tests conducted with plasma sprayed chrome carbide. Compared to the baseline results, no tribological benefit was achieved with the metallic bristle/solid lubricant tribopairs tested. To improve the performance of the solid lubricant coatings, issues regarding lubricant phase sizes (homogeneity), and composition need to be addressed.

Fellenstein, James A.↗

Single-Lever Power Control for General Aviation Aircraft Promises Improved Efficiency and Simplified Pilot Controls

General aviation research is leading to major advances in internal combustion engine control systems for single-engine, single-pilot aircraft. These advances promise to increase engine performance and fuel efficiency while substantially reducing pilot workload and increasing flight safety. One such advance is a single-lever power control (SLPC) system, a welcome departure from older, less user-friendly, multilever engine control systems. The benefits of using single-lever power controls for general aviation aircraft are improved flight safety through advanced engine diagnostics, simplified powerplant operations, increased time between overhauls, and cost-effective technology (extends fuel burn and reduces overhaul costs). The single-lever concept has proven to be so effective in preliminary studies that general aviation manufacturers are making plans to retrofit current aircraft with the technology and are incorporating it in designs for future aircraft.

Musgrave, Jeffrey L.↗

Assessment of Creep Capability of HSR-EPM Turbine Airfoil Alloys

The High Speed Civil Transport (HSCT) mission of the High Speed Research-Enabling Propulsion Materials (HSR-EPM) Program represented a unique challenge for turbine airfoil materials because the highest operating temperatures occur during climb and supersonic cruise. The accumulated hot time of an HSCT engine before overhaul is many thousands of hours. This is significantly different from subsonic engines, where the maximum operating temperatures occur during takeoff and thrust reverse after landing, and the accumulated hot time before overhaul is about 300 hr. The goal of airfoil alloy development under the HSR-EPM Program was to develop an alloy with a 75 F increase in creep rupture capability over the average Rene N5/PWA 1484 baseline. Airfoil alloy development under the HSR-EPM Program pursued a path that led to evolutionary mechanical behavior improvements, resulting from increased amounts of high density, refractory metals. The purpose of the present paper is to describe the experimental work that was performed at NASA Glenn Research Center after the HSR-EPM Program ended. Emphasis will be placed on the creep behavior of coated specimens, as well as on the development and progression of phase instabilities during creep deformation. Mitigation techniques that were used to reduce phase instabilities are also discussed. Most of the work described in this report was performed at NASA Glenn during the years 2000 and 2001.

MacKay, Rebecca A.↗

A Review of Engine Seal Performance and Requirements for Current and Future Army Engine Platforms

Sand ingestion continues to impact combat ground and air vehicles in military operations in the Middle East. The T-700 engine used in Apache and Blackhawk helicopters has been subjected to increased overhauls due to sand and dust ingestion during desert operations. Engine component wear includes compressor and turbine blades/vanes resulting in decreased engine power and efficiency. Engine labyrinth seals have also been subjected to sand and dust erosion resulting in tooth tip wear, increased clearances, and loss in efficiency. For the current investigation, a brief overview is given of the history of the T-700 engine development with respect to sand and dust ingestion requirements. The operational condition of labyrinth seals taken out of service from 4 different locations of the T-700 engine during engine overhauls are examined. Collaborative efforts between the Army and NASA to improve turbine engine seal leakage and life capability are currently focused on noncontacting, low leakage, compliant designs. These new concepts should be evaluated for their tolerance to sand laden air. Future R&D efforts to improve seal erosion resistance and operation in desert environments are recommended

Delgado, Irebert R.↗

Ground Processing Affordability for Space Vehicles

Launch vehicles and most of their payloads spend the majority of their time on the ground. The cost of ground operations is very high. So, why so often is so little attention given to ground processing during development? The current global space industry and economic environment are driving more need for efficiencies to save time and money. Affordability and sustainability are more important now than ever. We can not continue to treat space vehicles as mere science projects. More RLV's (Reusable Launch Vehicles) are being developed for the gains of reusability which are not available for ELV's (Expendable Launch Vehicles). More human-rated vehicles are being developed, with the retirement of the Space Shuttles, and for a new global space race, yet these cost more than the many unmanned vehicles of today. We can learn many lessons on affordability from RLV's. DFO (Design for Operations) considers ground operations during design, development, and manufacturing-before the first flight. This is often minimized for space vehicles, but is very important. Vehicles are designed for launch and mission operations. You will not be able to do it again if it is too slow or costly to get there. Many times, technology changes faster than space products such that what is launched includes outdated features, thus reducing competitiveness. Ground operations must be considered for the full product Lifecycle, from concept to retirement. Once manufactured, launch vehicles along with their payloads and launch systems require a long path of processing before launch. Initial assembly and testing always discover problems to address. A solid integration program is essential to minimize these impacts, as was seen in the Constellation Ares I-X test rocket. For RLV's, landing/recovery and post-flight turnaround activities are performed. Multi-use vehicles require reconfiguration. MRO (Maintenance, Repair, and Overhaul) must be well-planned--- even for the unplanned problems. Defect limits and standard repairs need to be in-place as well as easily added. Many routine inspections and maintenance can be like an aircraft overhaul. Modifications and technology upgrades should be expected. Another factor affecting ground operations efficiency is trending. It is essential for RLV's, and also useful for ELV's which fly the same or similar models again. Good data analysis of technical and processing performance will determine fixes and improvements needed for safety, design, and future processing. Collecting such data on new or low-frequency vehicles is a challenge. Lessons can be learned from the Space Shuttle, or even the Concorde aircraft. For all of the above topics, efficient business systems must be established for comprehensive program management and good throughput. Drawings, specifications, and manuals for an entire launch vehicle are often in different formats from multiple vendors, plus they have proprietary constraints. Nonetheless, the integration team must ensure that all data needed is compatible and visible to each appropriate team member. Ground processing systems for scheduling, tracking, problem resolution, etc. must be well laid-out. The balance between COTS (commercial off the shelf) and custom software is difficult. Multiple customers, vendors, launch sites, and landing sites add to the complexity of efficient IT (Information Technology) tools.

Ingalls, John↗

Evaluations of Damaged High-Pressure Compressor Blades in Two Turbine Engines of NASA DC–8

A series of flights were performed by the NASA DC-8 for the FIREX-AQ missions to observe the effects of wildfires and agricultural fires on air quality and climate in selected locations of the United States. Borescope evaluations after these flights indicated accelerated damage had occurred over this flight series to the blades in the high pressure compressor section of all four CFM56-2C1 turbine engines. This erosion and impact damage appeared to vary in severity, and appeared most severe for engines 3 and 4 located on the right wing of the DC-8.Engine 3 had the most flight hours and cycles since last overhaul of 7,152 h and 2,502 cycles. Engine 4 had the lowest flight hours and cycles since last overhaul of 1,354 h and 369 cycles. For these reasons, three noticeably damaged blades were selected from the high pressure compressor for each of these two engines, and then evaluated at NASA GRC using optical and scanning electron microscopy. Engine 3 compressor blades had both erosion and impact damage that were observed and characterized. The erosion damage was associated with embedded particles 13 μm to 42 μm in sectioned width, composed of varied compositions ranging from SiO2 to SiO2 also containing Ca, Mg, and Al (CMAS). The impact damage was associated with the impacts of larger objects at least 650 μm to 850 μm in width, but only small fragments 5 μm to 15 μm in sectioned width were embedded in the impact surface, also composed of SiO2 to SiO2 containing Ca, Mg, and Al (CMAS). On the other hand, engine 4 blades had only impact damage that was observed and characterized. This impact damage was associated with impacts of objects at least 1,480 μm to 2,080μm in width. Small fragments 5 μm to 15 μm in sectioned width were embedded in the impact surface. For one impact, the fragments were again composed of SiO2 to SiO2 containing Ca, Mg, and Al (CMAS). For two other impacts, the fragments were often composed of Fe, and less frequently Cu.

turbine↗

Multiscale Understanding and Architecture Design of High Energy/Power Lithium-Ion Battery Electrodes

Among various commercially available energy storage devices, lithium-ion batteries (LIBs) stand out as the most compact and rapidly growing technology. This multicomponent system operates on coupled dynamics to reversibly store and release electricity. With the hierarchical electrode architectures inside LIBs, versatile functionality can be realized by design, while considerable difficulties remain to be solved to fully exploit the capability of each constituent. With the rapid electrification of the transportation sector and an urgent need to overhaul electric grids in the context of renewable energy penetration, demands for concomitant high energy and high power batteries are continuously increasing. Although building an ideal battery requires effort from multiple scientific and engineering aspects, it is imperative to gain insight into multiscale transport behaviors arising in both spatial and temporal dimensions, and enable their harmonic integration inside the whole battery system. In this progress report, recent research efforts on characterizing and understanding transport kinetics in LIBs are reviewed covering a broad range of electrode materials and length scales. Further, to demonstrate the crucial role of such information in revolutionary electrode design, examples of innovative high energy/power electrodes are provided with their unique hierarchical porous architectures highlighted. To conclude, perspectives on further approaches toward advanced thick electrode designs with fast kinetics and tailored properties are discussed.

25 ENERGY STORAGE↗

Optimal operation of multi-plant steam district heating systems for enhanced efficiency and sustainability

Despite their crucial role in supplying heat and power to universities, industries, and healthcare facilities, many steam-based district heating systems rely on outdated control methods. Among these, multi-central plant districts are particularly challenging due to the complexities of coordinating multiple plants, optimizing load distributions, and managing system downtime. In response, new operational strategies are developed to enhance the efficiency and sustainability of steam districts while utilizing existing resources. These strategies include reducing plant operational pressure without compromising the reliable supply to buildings and optimizing load allocation across multiple plants. The load allocation considers boiler part-load efficiency, runtime, network losses, and building pressure set points, and is compared with traditional multi-boiler controls. To support this exploration, new dynamic Modelica models are developed. In addition, methods to reduce modeling complexities are incorporated, enhancing their suitability for practical applications. A holistic district-wide analysis using a real university case study demonstrates a 4.7% fuel savings by lowering boiler operational pressure from 900 kPa to 600 kPa, along with a 13.3% reduction in condensation losses across the distribution network. Furthermore, the load allocation approach results in a 13.1% reduction in fuel consumption during peak winter periods and 15.3% during shoulder periods, with corresponding decreases in carbon emissions and fuel costs. This approach can also save maintenance costs by reducing the boiler runtime by 49.6%. In conclusion, this research underscores the benefits of retrofitting aging steam district heating systems, offering immediate operational improvements by enhancing efficiency, meeting regulatory compliance, and extending infrastructure lifespans while delaying costly overhauls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Performance of the LHCb muon detector in Run 3

In Run 3 of the LHC, the instantaneous luminosity at the LHCb interaction point has been increased by a factor of five, from to $\mathscr{L}$ = 4 x 10 32 cm -2 s -2 to $\mathscr{L}$ = 2 x 10 33 cm -2 s -1 . Several hardware interventions, including a complete overhaul of the readout electronics, have been carried out on the muon detector. The muon identification algorithms in the software trigger were improved with the aim of ensuring Run 2 performance under a higher particle rate. The operation and calibration of the upgraded muon detector are presented. The muon detection efficiency and muon identification performance are evaluated on data calibration samples collected during the year 2024. A muon identification efficiency above 90% with sub-percent hadron misidentification probability is achieved by exploiting the pattern of hits in the muon detector.

Gaseous detectors↗

Verifying raytracing/Fokker–Planck lower-hybrid current drive predictions with self-consistent full-wave/Fokker–Planck simulations

Raytracing/Fokker–Planck (FP) simulations used to model lower-hybrid current drive (LHCD) often fail to reproduce experimental results, particularly when LHCD is weakly damped. A proposed reason for this discrepancy is the lack of ‘full-wave’ effects, such as diffraction and interference, in raytracing simulations and the breakdown of the raytracing approximation. Previous studies of LHCD using non-Maxwellian full-wave/FP simulations have been performed, but these simulations were not self-consistent and enforced power conservation between the FP and full-wave code using a numerical rescaling factor. Here, we have created a fully self-consistent full-wave/FP model for LHCD that is automatically power conserving. This was accomplished by coupling an overhauled version of the non-Maxwellian TORLH full-wave solver and the CQL3D FP code using the Integrated Plasma Simulator. We performed converged full-wave/FP simulations of Alcator C-Mod discharges and compared them with raytracing. We found that excellent agreement in the power deposition profiles from raytracing and TORLH could be obtained, however, TORLH had somewhat lower current drive efficiency and broader power deposition profiles in some cases. This discrepancy appears to be a result of numerical limitations present in the TORLH model and a small amount of diffractional broadening of the TORLH wave spectrum. Our results suggest full-wave simulation of LHCD is likely not necessary as diffraction and interference represented only a small correction that could not account for the differences between simulations and experiment.

Physics↗

Data-Driven Strategies for Accelerated Materials Design

The ongoing revolution of the natural sciences by the advent of machine learning and artificial intelligence sparked significant interest in the material science community in recent years. The intrinsically high dimensionality of the space of realizable materials makes traditional approaches ineffective for large-scale explorations. Modern data science and machine learning tools developed for increasingly complicated problems are an attractive alternative. An imminent climate catastrophe calls for a clean energy transformation by overhauling current technologies within only several years of possible action available. Tackling this crisis requires the development of new materials at an unprecedented pace and scale. For example, organic photovoltaics have the potential to replace existing silicon-based materials to a large extent and open up new fields of application. In recent years, organic light-emitting diodes have emerged as state-of-the-art technology for digital screens and portable devices and are enabling new applications with flexible displays. Reticular frameworks allow the atom-precise synthesis of nanomaterials and promise to revolutionize the field by the potential to realize multifunctional nanoparticles with applications from gas storage, gas separation, and electrochemical energy storage to nanomedicine. In the recent decade, significant advances in all these fields have been facilitated by the comprehensive application of simulation and machine learning for property prediction, property optimization, and chemical space exploration enabled by considerable advances in computing power and algorithmic efficiency. In this Account, we review the most recent contributions of our group in this thriving field of machine learning for material science. We start with a summary of the most important material classes our group has been involved in, focusing on small molecules as organic electronic materials and crystalline materials. Specifically, we highlight the data-driven approaches we employed to speed up discovery and derive material design strategies. Subsequently, our focus lies on the data-driven methodologies our group has developed and employed, elaborating on high-throughput virtual screening, inverse molecular design, Bayesian optimization, and supervised learning. We discuss the general ideas, their working principles, and their use cases with examples of successful implementations in data-driven material discovery and design efforts. Furthermore, we elaborate on potential pitfalls and remaining challenges of these methods. Finally, we provide a brief outlook for the field as we foresee increasing adaptation and implementation of large scale data-driven approaches in material discovery and design campaigns.

36 MATERIALS SCIENCE↗

Modes of Disorder in Poly(carbon monofluoride)

Poly(carbon monofluoride), or (CF) n , is a layered fluorinated graphite material consisting of nanosized platelets. In this work, we present experimental multidimensional solid-state NMR spectra of (CF)n, supported by density functional theory (DFT) calculations of NMR parameters, which overhauls our understanding of structure and bonding in the material by elucidating many ways in which disorder manifests. We observe strong 19 F NMR signals conventionally assigned to elongated or “semi-ionic” C–F bonds and find that these signals are in fact due to domains where the framework locally adopts boat-like cyclohexane conformations. We calculate that C–F bonds are weakened but are not elongated by this conformational disorder. Exchange NMR suggests that conformational disorder avoids platelet edges. We also use a new J-resolved NMR method for disordered solids which provides molecular-level resolution of highly fluorinated edge states. Strings of consecutive difluoromethylene groups at edges are relatively mobile. Topologically distinct edge features, including zigzag edges, crenellated edges, and coves are resolved in our samples by solid-state NMR. Disorder should be controllable in a manner dependent on synthesis, affording new opportunities for tuning the properties of graphite fluorides.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Evolution of DUNE’s Production System

The DUNE experiment will start running in 2029 and record 30 PB/year of raw waveforms from Liquid Argon TPCs and photon detectors. The size of individual readouts can range from 100 MB to a typical 8 GB full readout of the detector, and even 100 TB for extended readouts from supernova candidates. These data then need to be cataloged, stored and distributed for processing worldwide. This massive amount of data and a heterogeneous computing environment necessitates a powerful and robust distributed computing infrastructure. In the process of building up that infrastructure, DUNE’s production system has recently undergone an overhaul, in which it has integrated 1) a new workflow management system (justIN) 2) a new data catalog (MetaCat) and 3) a state-of-the-art data management system (Rucio). Simulations of DUNE’s Far Detector and its prototypes ProtoDUNE Horizontal Drift (ProtoDUNE-HD) and ProtoDUNE Vertical Drift (ProtoDUNE-VD), as well as data from ProtoDUNE-HD serve as the first tests of this infrastructure.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Technoeconomic Design Optimization for Fast Reactors. Part II: Impact of Technoeconomic Constraints on Optimal Design

There is a current drive toward optimizing reactors, particularly small/micro reactors to minimize cost and maximize performance. Previous work has investigated the development of technoeconomic workflows for the design optimization of pool-type fast reactors that aim to deploy into district energy grids. Initial scoping studies verified that the workflow was capable of capturing design trends throughout a variety of design configurations and problem formulations while remaining sufficiently flexible. In this paper, this methodology is applied to understand how cost functions and technoeconomic constraints can drive optimal reactor design. Specifically, the UPu10Zr-fueled fast reactor model from Part I is adapted to include changes in the fissile content limits, control rod worth limits, control rod drive cost, and assumed fuel form. In the case of constraint relaxation at fixed power (fissile content and control rod worth limits), cost sensitivities of 5% to 10% were uncovered. Multi-objective optimization at varying reactor power levels with individualized control rod drives for each assembly (as opposed to one operational and one safety drive) increased cost by $\$10$ to $\$25$ million and substantially altered the optimal core geometry, favoring geometries with substantially fewer control rod placements relative to baseline optimization. Finally, a multi-objective optimization was performed at varying power levels with the fuel form overhauled to metallic, high-assay low-enriched uranium–based U10Zr with more refined fuel cost models. In the case of uranium fueling, the costs increased by at least $50 million relative to the baseline case. Furthermore, economic fuel zoning and lower reactivity swing cores were recovered. Each case serves to demonstrate the value of applying technoeconomic workflows to initial reactor design scoping studies to better understand the trade-off for a proposed concept between different design options.

Argonne Reactor Computation (ARC) codes↗

Status and perspectives of the ICARUS experiment at the Fermilab Short Baseline Neutrino program

In this study, the ICARUS collaboration has employed the 760 t T600 detector in a successful three-year physics run at the underground LNGS laboratory, performing a sensitive search for LSND-like anomalous ν e appearance in the CERN Neutrino to Gran Sasso beam, which contributed to the constraints on the allowed neutrino oscillation parameters to a narrow region around Δm 2 ~ 1 eV 2 . After a significant overhaul at CERN, the T600 detector has been installed at Fermilab. In 2020 the cryogenic commissioning began with detector cool down, liquid Argon filling and recirculation. ICARUS then started its operation collecting the first neutrino events from the Booster Neutrino Beam (BNB) and the Neutrinos at the Main Injector (NuMI) beam off-axis, which were used to test the ICARUS event selection, reconstruction and analysis algorithms. ICARUS successfully completed its commissioning phase in June 2022, moving then to data taking for neutrino oscillation physics, aiming at first to either confirm or refute the claim by Neutrino-4 short-baseline reactor. ICARUS will also jointly search for evidence of sterile neutrinos together with the Short-Baseline Near Detector, within the Fermilab Short-Baseline Neutrino program experiment, and will perform measurements of neutrino cross sections with both beams and several Beyond Standard Model searches with the NuMI beam. In this paper, the main technical achievements of the ICARUS detector subsystems (Time Projection Chambers, Light Detection System, Cosmic Ray Tagger, Trigger and Data Acquisition) obtained with both BNB and NuMI neutrino beams during the commissioning phase, will be presented in terms of the overall detector performance and capability to select and reconstruct neutrino events.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

ALICE upgrades during the LHC Long Shutdown 2

A Large Ion Collider Experiment (ALICE) has been conceived and constructed as a heavy-ion experiment at the LHC. During LHC Runs 1 and 2, it has produced a wide range of physics results using all collision systems available at the LHC. In order to best exploit new physics opportunities opening up with the upgraded LHC and new detector technologies, the experiment has undergone a major upgrade during the LHC Long Shutdown 2 (2019–2022). This comprises the move to continuous readout, the complete overhaul of core detectors, as well as a new online event processing farm with a redesigned online-offline software framework. These improvements will allow to record Pb-Pb collisions at rates up to 50 kHz, while ensuring sensitivity for signals without a triggerable signature.

47 OTHER INSTRUMENTATION↗

Accelerate microstructure evolution simulation using graph neural networks with adaptive spatiotemporal resolution

Abstract Surrogate models driven by sizeable datasets and scientific machine-learning methods have emerged as an attractive microstructure simulation tool with the potential to deliver predictive microstructure evolution dynamics with huge savings in computational costs. Taking 2D and 3D grain growth simulations as an example, we present a completely overhauled computational framework based on graph neural networks with not only excellent agreement to both the ground truth phase-field methods and theoretical predictions, but enhanced accuracy and efficiency compared to previous works based on convolutional neural networks. These improvements can be attributed to the graph representation, both improved predictive power and a more flexible data structure amenable to adaptive mesh refinement. As the simulated microstructures coarsen, our method can adaptively adopt remeshed grids and larger timesteps to achieve further speedup. The data-to-model pipeline with training procedures together with the source codes are provided.

36 MATERIALS SCIENCE↗

Pressure-temperature equation of state of Al 2 ⁢O 3 up to 14 Mbar and 40 kK

Sapphire (Al 2 ⁢O 3 ), known for its remarkable incompressibility at ambient conditions, plays a pivotal role in both static and dynamic compression research. Accurately characterizing its equation of state (EoS) is essential for these applications. Here, we present a complete Hugoniot of Al 2 ⁢ O 3 as locus of experimentally assessed, high-precision, pressure, density and temperature states up to 14 Mbar and 43 kK. The Hugoniot is established with single shock experiments using magnetically launched hyper velocity flyers on the Z Accelerator at Sandia National Laboratories. We explore principal Hugoniot states at very high shock 𝑇 and 𝑝 in the solid phase, tracking the solid-liquid boundary and culminating at 2.4-fold compression, where data provides a direct constraint on the liquid phase. Corresponding shock release data probe thermodynamic states complementary to the Hugoniot and place additional constraints on tabular EoS models. Our findings indicate a significant deviation from existing tabular EoS models for Al 2 ⁢ O 3 dictating a comprehensive overhaul. We develop two advanced EoSs for Al 2 ⁢ O 3 the SESAME 97412 model, featuring an extensive phase diagram that includes three solid phases and the liquid phase, and the updated LEOS 2200m2 model. EoS development is assisted with Quantum Molecular Dynamics simulations. Our experimental data allows for stringent testing of our EoSs. Both models accurately capture the Hugoniot of Al 2 ⁢O 3 up to the highest pressures and temperatures. Rigorous experimental determination of extreme pressures and temperatures, paired with sophisticated models, advances the frontier of EoS development beyond 1 terapascal.

Kalita, Patricia [Sandia National Laboratories (SN↗