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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Scalable aqueous-phase fabrication of reduced graphene oxide nanofiltration membranes by an integrated roll-to-roll (R2R) process

Economic fractionation of multicomponent biomass-derived streams is a key challenge in biobased fuels and chemicals production. Kraft black liquor (BL) is generated at ~1 billion tons/yr globally from biomass pulping and contains ~15wt% total solids including lignin, hemicellulose fragments, and inorganics. Membrane-based BL concentration is attractive but challenged by low solute rejections and poor stability in BL, which combines alkaline pH (~13), high dissolved solids content (15+ wt%) and high temperature (70–85°C). Here we discuss the scaled fabrication and characterization of reduced graphene oxide (rGO) nanofiltration membranes by slot die coating on a roll-to-roll (R2R) with integrated vacuum filtration. Here, we obtain high-quality 90×30 cm rGO membranes (referred to as “R2R-rGO membranes” in this work) with ~100 nm average thickness supported on porous poly(ethersulfone) (PES) sheets, and an effective area of 2700cm 2 . We present characterizations of their microstructure and uniformity as mapped over large areas by scanning electron microscopy (SEM), ellipsometry, adhesion test and X-ray photoelectron spectroscopy (XPS). The constructed ellipsometry model for the rGO membrane/PES substrate composite was successfully applied to 48 different locations of the R2R-rGO membranes. The R2R-rGO membranes showed >98% lignin rejection with a steady state flux of ~12 LMH at 50bar in a 15.7wt% total solids (TS) kraft BL stream at 72°C and 2–3 gal/min crossflow rates. Slot die coating on a R2R platform with integrated vacuum filtration can enable rapid fabrication of high-quality GO membranes at scale without organic solvents or volatile organic compounds.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

3x3 array module of 8×8×32 mm 3 position-sensitive virtual frisch-grid CdZnTe detectors for imaging and spectroscopy of cosmic gamma-rays

Here, we evaluated the performance of the 3x3 array of 32-mm long position-sensitive virtual Frisch-grid (VFG) CdZnTe (CZT) detectors read out by the IDEAS GDS-100 data acquisition system. The array is a mechanically solid module designed for integration into a large effective area gamma-ray telescope proposed for imaging and spectroscopy of cosmic gamma-rays. The array employs the bar-shaped 8x8x32 mm 3 CZT crystals which recently became available from Redlen Technologies, Inc. and Kromek-eV Group PLC at affordable costs. The waveform sampling IDE3421 application-specific integrated circuit (ASIC), developed by the University of Michigan and IDEAS for CZT pixel detectors, was adapted to capture the signals from the array's VFG detectors. We showed good spectral performance of the Redlen detectors with an energy resolution of <1% FWHM at 662 keV and slightly poorer performance of the Kromek-eV detectors with a resolution of <2% measured at a reduced temperature of 13 °C. By testing the same detectors as single devices using hybrid charge-sensitive preamplifiers, we demonstrated improved energy resolutions at a normal temperature of ~25°C: <1% and 1.3-1.7%, respectively. However, the Kromek-eV detectors did not perform as well as the Redlen ones. We explained this by the space charge formation (polarization) decreasing the electric field and the electron drift times. The polarization was likely caused by the high injections of holes from the anode contacts. The absence of polarization in Redlen detectors suggested that the quality of the contacts might have played a role in this case.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Clash of the titans: ultra-high energy KM3NeT event versus IceCube data

KM3NeT has reported the detection of a remarkably high-energy through-going muon. Lighting up about a third of the detector, this muon likely originated from a neutrino exceeding 10 PeV in energy. The crucial question we need to answer is where this event comes from and what its source is. Intriguingly, IceCube has been operating with a much larger effective area for a considerably longer time, yet it has not reported neutrinos above 10 PeV. We quantify the tension between the KM3NeT event and the absence of similar high-energy events in IceCube under various assumptions of the origin for the neutrino including the isotropic diffuse flux, cosmogenic flux, and a steady or transient point source. Through a detailed analysis, we determine the most likely neutrino energy to be in the range of 23 – 2400 PeV, and find a tension between the experiments ranging from 3.6 to 3.1 σ for diffuse origins and 2.9 to 2.0 σ for point sources. The lack of observation of high-energy events in IceCube seriously challenges the explanation of this event coming from any known diffuse fluxes. Our results indicate the KM3NeT event is likely the first observation of a new astrophysical source.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Delving into the depths of NGC 3783 with XRISM II. Cross-calibration of X-ray instruments used in the large, multi-mission observational campaign

Context. Accurate X-ray spectroscopic measurements are fundamental for deriving basic physical parameters of the most abundant baryon components in the Universe. The plethora of X-ray observatories currently operational enables a panchromatic view of the high-energy emission of celestial sources. However, uncertainties in the energy-dependent calibration of the instrument transfer functions (e.g. the effective area, energy redistribution, or gain) can limit - and historically, did limit - the accuracy of X-ray spectroscopic measurements. Aims. We revised the status of the cross-calibration among the scientific payload on board four operation missions: Chandra, NuSTAR, XMM-Newton, and the recently launched XRISM. XRISM carries the micro-calorimeter Resolve, which yields the best energy resolution at energies ≥2 keV. For this purpose, we used the data from a 10-day-long observational campaign targeting the nearby active galactic nucleus NGC 3783, carried out in July 2024. Methods. We present a novel model-independent method for assessing the cross-calibration status that is based on a multi-node spline of the spectra with the highest-resolving power (XRISM/Resolve in our campaign). We also estimated the impact of the intrinsic variability of NGC 3783 on the cross-calibration status due to the different time coverages of participating observatories and performed an empirical reassessment of the Resolve throughput at low energies. Results. Based on this analysis, we derived a set of energy-dependent correction factors of the observed responses, enabling a statistically robust analysis of the whole spectral dataset. They will be employed in subsequent papers describing the astrophysical results of the campaign. Aims. We revised the status of the cross-calibration among the scientific payload on board four operation missions: Chandra, NuSTAR, XMM-Newton, and the recently launched XRISM. XRISM carries the micro-calorimeter Resolve, which yields the best energy resolution at energies ≥2 keV. For this purpose, we used the data from a 10-day-long observational campaign targeting the nearby active galactic nucleus NGC 3783, carried out in July 2024. Methods. We present a novel model-independent method for assessing the cross-calibration status that is based on a multi-node spline of the spectra with the highest-resolving power (XRISM/Resolve in our campaign). We also estimated the impact of the intrinsic variability of NGC 3783 on the cross-calibration status due to the different time coverages of participating observatories and performed an empirical reassessment of the Resolve throughput at low energies. Results. Based on this analysis, we derived a set of energy-dependent correction factors of the observed responses, enabling a statistically robust analysis of the whole spectral dataset. They will be employed in subsequent papers describing the astrophysical results of the campaign.

Active Galactic Nuclei, individual: NGC 3783↗
DOE OSTI2026

The pathfinder X-Ray axion telescope for the International Axion Observatory (IAXO) and axion searches at the CERN Axion Solar Telescope (CAST)

The axion, a hypothetical pseudo-scalar particle proposed by Peccei and Quinn to resolve the strong CP problem in quantum chromodynamics, remains one of the most compelling dark matter candidates. Axions and Axion-Like Particles (ALPs) are characterized by a broad and largely unconstrained parameter space in mass and coupling strength, motivating extensive experimental searches. The International Axion Observatory (IAXO) is a next-generation axion helioscope designed to achieve over an order of magnitude improvement in sensitivity to the axion-photon coupling constant gaγ relative to previous experiments such as the CERN Axion Solar Telescope (CAST). IAXO will employ large-scale superconducting magnets, precision x-ray optics, and ultra-low-background detectors to search for solar axions produced primarily via the Primakoff effect. This work presents the design and performance of the IAXO pathfinder x-ray optic, a technological demonstrator that validated the optical concepts for IAXO through axion searches at CAST. Comprehensive ray-tracing simulations and experimental measurements were conducted to assess the optic's effective area, detection efficiency, and background suppression capabilities. Deployed at CAST in conjunction with Micromegas and GridPix detectors, the Pathfinder demonstrated record-setting sensitivity to both gaγ and the axion-electron coupling gae, establishing the most stringent laboratory constraints on solar axions to date. These results confirm the viability of the IAXO optical design and detector concept, providing a critical technological benchmark that informs the ongoing development of the BabyIAXO and full-scale IAXO telescopes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Dark energy survey year 3 results: weak lensing shape catalogue

ABSTRACT We present and characterize the galaxy shape catalogue from the first 3 yr of Dark Energy Survey (DES) observations, over an effective area of 4143 deg2 of the southern sky. We describe our data analysis process and our self-calibrating shear measurement pipeline metacalibration, which builds and improves upon the pipeline used in the DES Year 1 analysis in several aspects. The DES Year 3 weak-lensing shape catalogue consists of 100 204 026 galaxies, measured in the riz bands, resulting in a weighted source number density of neff = 5.59 gal arcmin−2 and corresponding shape noise σe = 0.261. We perform a battery of internal null tests on the catalogue, including tests on systematics related to the point spread function (PSF) modelling, spurious catalogue B-mode signals, catalogue contamination, and galaxy properties.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

In-orbit performance of the soft X-ray imaging telescope Xtend aboard XRISM

Here, we present a summary of the in-orbit performance of the soft X-ray imaging telescope Xtend onboard the X-Ray Imaging and Spectroscopy Mission (XRISM), based on in-flight observation data, including first-light celestial objects, calibration sources, and results from the cross-calibration campaign with other currently operating X-ray observatories. XRISM/Xtend has a large field of view of ${38{^{\prime }_{.}}5}$ $\times$ ${38{^{\prime }_{.}}5}$, covering an energy range of 0.4–13 keV, as demonstrated by the first-light observation of the galaxy cluster Abell 2319. It also features an energy resolution of 170–180 eV at 6 keV, which meets the mission requirement and enables us to resolve He-like and H-like Fe K$\alpha$ lines. Throughout the observation during the performance verification phase, we confirm that two issues identified in the Soft X-ray Imager (SXI) onboard the previous Hitomi mission—light leakage and crosstalk events—are addressed and suppressed in the case of Xtend. A joint cross-calibration observation of the bright quasar 3C 273 results in an effective area measured to be $\sim$420 cm$^{2}$ at1.5 keV and $\sim$310 cm$^{2}$ at 6.0 keV, which matches values obtained in ground tests. We also continuously monitor the health of Xtend by analyzing overclocking data, calibration source spectra, and day-Earth observations; the readout noise is stable and low, and contamination is negligible even one year after launch. A low background level compared with other major X-ray instruments onboard satellites, combined with the largest grasp ($\Omega _{\rm eff}\sim 60$ cm$^2$ deg$^2$) of Xtend, will not only support Resolve analysis, but also enable significant scientific results on its own. This includes near-future follow-up observations and transient searches in the context of time-domain and multi-messenger astrophysics.

instrumentation: detectors: Xtend↗
DOE OSTI2022

Dark Energy Survey Year 3 results: Cosmology with moments of weak lensing mass maps

We present a cosmological analysis using the second and third moments of the weak lensing mass (convergence) maps from the first three years of data (Y3) data of the Dark Energy Survey. The survey spans an effective area of 4139 square degrees and uses the images of over 100 million galaxies to reconstruct the convergence field. The second moment of the convergence as a function of smoothing scale contains information similar to standard shear 2-point statistics. The third moment, or the skewness, contains additional non-Gaussian information. The data is analyzed in the context of the Λ CDM model, varying five cosmological parameters and 19 nuisance parameters modeling astrophysical and measurement systematics. Our modeling of the observables is completely analytical, and has been tested with simulations in our previous methodology study. We obtain a 1.7% measurement of the amplitude of fluctuations parameter S 8 ≡ σ 8 ( Ω m / 0.3 ) 0.5 = 0.784 ± 0.013 . The measurements are shown to be internally consistent across redshift bins, angular scales, and between second and third moments. In particular, the measured third moment is consistent with the expectation of gravitational clustering under the Λ CDM model. The addition of the third moment improves the constraints on S 8 and Ω m by ∼ 15 % and ∼ 25 % compared to an analysis that only uses second moments. We compare our results with Planck constraints from the cosmic microwave background, finding a 2.2 – 2.8 σ tension in the full parameter space, depending on the combination of moments considered. The third moment, independently, is in 2.8 σ tension with Planck, and thus provides a cross-check on the analyses of 2-point correlations.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Improved Constraints on Primordial Gravitational Waves using Planck , WMAP, and BICEP/ Keck Observations through the 2018 Observing Season

Here, we present results from an analysis of all data taken by the BICEP2, Keck Array, and BICEP3 CMB polarization experiments up to and including the 2018 observing season. We add additional Keck Array observations at 220 GHz and BICEP3 observations at 95 GHz to the previous 95/150/220 GHz dataset. The Q/U maps now reach depths of 2.8, 2.8, and 8.8 μK CMB arcmin at 95,150, and 220 GHz, respectively, over an effective area of ≈ 600 square degrees at 95 GHz and ≈ 400 square degrees at 150 and 220 GHz. The 220 GHz maps now achieve a signal-to-noise ratio on polarized dust emission exceeding that of Planck at 353 GHz. We take auto- and cross-spectra between these maps and publicly available WMAP and Planck maps at frequencies from 23 to 353 GHz and evaluate the joint likelihood of the spectra versus a multicomponent model of lensed ΛCDM + r + dust + synchrotron + noise . The foreground model has seven parameters, and no longer requires a prior on the frequency spectral index of the dust emission taken from measurements on other regions of the sky. This model is an adequate description of the data at the current noise levels. The likelihood analysis yields the constraint r 0.05 < 0.036 at 95% confidence. Running maximum likelihood search on simulations we obtain unbiased results and find that σ(r) = 0.009 . These are the strongest constraints to date on primordial gravitational waves.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Hoop Tensile Failure Stress of 500 µm-Diameter Ceramic Spheres

The tensile failure stress of a brittle-material sphere is important to the survival of the sphere itself but is particularly relevant to systems that employ such spheres for applications in which the sphere exterior is subjected to tension during system fabrication or operation. That maximum hoop or tangential stress can be measured by diametrally compressing a C-sphere specimen directly machined from such spheres. This combination of specimen geometry and test method was conceived at Oak Ridge National Laboratory around 20 years ago. Although the C-sphere geometry has been tested with larger spheres, the ease and efficacy of its testing are unknown for submillimeter sphere diameters. To consider this, C-sphere specimens were machined from yttria-stabilized zirconia (YSZ) spheres of ∼500 µm diameter. The maximum (hoop or tangential) tensile stress was determined as a function of compressive failure force and specimen dimensions using finite element analysis. Companion effective area and volume as a function of Weibull modulus were computed. Hoop tensile failure stresses were then measured and fractography conducted to examine flaw type and location and to estimate the mirror constant of this YSZ grade. This novel study demonstrates that hoop tensile failure stress can be determined with sub-millimeter brittle-material spheres.

Delia, Daniel [ORNL] (ORCID:0000000209023239)↗
DOE OSTI2025

Resolve instrument onboard XRISM: design, integration, and instrument test results

The Resolve instrument onboard the X-Ray Imaging and Spectroscopy Mission (XRISM) consists of an array of 6 × 6 silicon-thermistor microcalorimeters cooled down to 50 mK and a high-throughput X-ray mirror assembly (XMA) with a focal length of 5.6 m. XRISM is a recovery mission of ASTRO-H/Hitomi, and the Resolve instrument is a rebuild of the ASTRO-H Soft X-ray spectrometer (SXS) and the Soft X-ray Telescope (SXT) that achieved energy resolution of ∼ 5 eV FWHM on orbit, with several important changes based on lessons learned from ASTRO-H. The flight models of the Dewar and the electronics boxes were fabricated, and the instrument test and calibration were conducted in 2021. By tuning the cryocooler frequencies, energy resolution better than 4.9 eV FWHM at 6 keV was demonstrated for all 36 pixels and high-resolution grade events, as well as energy-scale accuracy better than 2 eV up to 30 keV. The immunity of the detectors to microvibration, electrical conduction, and radiation was evaluated. The instrument was delivered to the spacecraft system in April 2022. The XMA was tested and calibrated separately. Its angular resolution is 1.27′, and the effective area of the mirror itself is 570 cm 2 at 1 keV and 424 cm 2 at 6 keV. We report the design and the major changes from the ASTRO-H SXS, the integration, and the results of the instrument test.

X-ray↗
DOE OSTI2020

Performance simulation of the soft gamma-ray concentrator

The soft gamma-ray concentrator is a telescope mission concept utilizing a suitable arrangement of bent multilayer structures of alternating low- and high-density materials. This lens is able to channel gamma-ray photons via total external reflection and concentrate the incident radiation to a point. The channeling technique offers the potential for concentrating gamma rays with focal lengths <10 m and energies >100 keV, beyond the reach of current grazing-incidence hard x-ray mirrors. For the performance estimation of such an instrument, we have developed a flexible set of computer modeling tools to compute the optical properties of multilayer structures, predict the channeling efficiency for a given multilayer configuration, and aid in the optimization of potential gamma-ray concentrator-based telescope designs. This modeling includes the multilayer optical properties calculated by the IMD software, the ray tracing using an IDL code, and the focal plane detector simulation by MEGAlib. We illustrate the potential of this approach by presenting simulated astronomical observations from a balloon-borne platform. The final result, including simulated effective area, instrument sensitivity, and polarization performance, shows that the gamma-ray concentrator will provide greatly increased sensitivity for next-generation soft gamma-ray missions with modest cost and complexity.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Iridium thin-film coatings for the BabyIAXO hybrid X-ray optic

Reflective coatings are an essential feature of X-ray telescopes. Their overall performance relies heavily on substrate compatibility and how well they conform to the optics assembly processes. We use X-ray reflectometry (XRR) to demonstrate the compatibility of shaping flat substrates coated with iridium, and show that specular and nonspecular reflectance before and after shaping is on par with traditional hot-slumped coated substrates. From 1.487 and 8.048 k e V measurements, we find that the substrates have rms roughness of 0.38 n m and magnetron sputtered iridium deposits with rms surface roughness of 0.27 − <#comment/> 0.35 n m . A hydrocarbon overlayer from atmospheric contamination is present with a thickness of 1.4 – 1.6 n m and a density of 1.2 − <#comment/> 1.6 g / c m 3 . Both the traditional hot slumped and the flat substrates undergoing post-coating shaping have a similar characteristic surface morphology and are equally well-suited for use with X-ray optics. Finally, we demonstrate by simulation the improved effective area achieved by using a low-Z overlayer, and illustrate the performance of a hybrid optic coated with optimized bilayers for a Primakoff axion spectrum emitted by the sun.

Henriksen, Peter L. (ORCID:0000000259031878)↗
DOE OSTI2023

Multi-parameter distributed fiber optic sensing using double-Brillouin peak fiber in Brillouin optical time domain analysis

In this paper, we demonstrate a multi-parameter fiber sensing system based on stimulated Brillouin scattering in a double-Brillouin peak specialty fiber with enhanced Brillouin gain response. The amplitude level of the second Brillouin gain peak, which originated from the higher-order acoustic modes, has been improved with an approximately similar amplitude level to the first Brillouin gain peak from the fundamental acoustic mode. Compared to other multi-Brillouin peak fibers presented in the literature, the proposed fiber significantly reduces the measured Brillouin frequency shift error, thus improving strain and temperature accuracies. By utilizing the sensitivity values of the strain and temperature associated with each Brillouin gain spectrum (BGS) peak, a successful discriminative measurement of strain and temperature is performed with an accuracy of ±13 μɛ, and ±0.5 °C, respectively. The proposed double-Brillouin peak fiber appears to be a possible alternative to other multi-BGS peak fibers, for instance, large effective area fiber and dispersion compensating fibers, which are inherently accompanied by large measurement errors due to the weak Brillouin gain values originating from the higher-order acoustic modes. The demonstrated results show different strain and temperature coefficients of 47 kHz/µɛ, 1.15 MHz/°C for peak 1 and 51 kHz/µɛ, 1.37 MHz/°C for peak 2. Moreover, the enhanced BGS peak gains having nearly the same amplitude levels enable the discriminative measurement of strain and temperature. Such fibers in Brillouin interrogation eliminate the need for complex monitoring setups and reduce measurement errors. We recommend that for long-distance natural gas pipeline monitoring, where discriminative strain and temperature measurement is crucial, the proposed double-Brillouin peak fiber can be highly beneficial.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Modular Adaptive Packing for Integrally Cooled Absorbers

Process intensification is one cornerstone in ION Clean Energy’s (ION) efforts to lowering CO2 capture cost. ION has modeled, designed, and fabricated an innovative gas-liquid contactor known as Modular Adaptive Packing (MAP). During two successful SBIR Phase I and II projects entitled: “Rapid Design and Testing of Novel Gas-Liquid Contacting Devices for Post-Combustion CO2 Capture via 3D-printing”, ION developed and proved this new technology at bench scale. MAP, a 3D-printed lattice-structured packing, combines the absorber gas/liquid contactor with an innovative in-situ heat-exchanger. Thanks to the capabilities of 3D-printing, the lattice structure of MAP contains hollow channels through which coolant water can be pumped to remove the heat of reaction from CO2 absorption. ION refers to this novel method of heat exchange as intracooling. After 25.4 cm (10 in) diameter MAP modules were fabricated, ION built and tested a packing characterization rig at its pilot facility in Boulder, Colorado, U.S.A. To provide baseline results for the characterization rig, ION tested Sulzer’s Mellapak™ 250Y (MP250Y) as a standard structured packing. ION’s MAP was then compared directly to the baseline MP250Y packing to evaluate key indicators including pressure drop, liquid hold-up, and effective area. MAP has a higher pressure drop than MP250Y at the same gas velocities in addition to greater liquid holdup. However, ION found that MAP displays a higher wetting coverage of 93% compared to 65% for MP250Y and reduces shearing forces that result in undesirable droplet formation. Using Optimized Gas Treating’s (OGT) rate-based simulation software ProTreat®, a conceptual evaluation of MAP was modeled for a CO2 absorber using 30 wt% MEA solvent over a range of lean loadings at 90% CO2 capture from a coal-fired power plant. ION modeled a 25-meter column absorber for both the standard MP250Y packing and a hybrid column. The hybrid absorber contained 10 m of MP250Y packing at the top and bottom with the middle 5 meters comprised of MAP. Compared to a traditional intercooled absorber, MAP can remove 22% more heat and increase overall MEA carrying capacity by 4% without increasing overall pressure drop.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

GEMINI Case Study

Sandia's GEMINI-Scout Mine Rescue Robot is an unmanned ground vehicle designed to enter potentially hazardous environments to explore, assess, and evaluate dangerous situations first responders may face when conducting a rescue mission. GEMINI is approximately four feet long and two feet tall, which enables the robot to maneuver through small locations on rough terrains caused by earthquakes, fires, or radiological incidents. GEMINI uses track propulsion to climb stairs, travel through gravel and sand pits, pivot in place, and traverse 45-degree climbs with few problems. Furthermore, the vehicle's dual tracked-chassis design allows it to operate in hostile, dark, muddy, high-temperature, and explosive debris-strewn environments, while maintaining efficient ground mobility. The mobility and modularity of the vehicle allow for easy integration of sensors to conduct gas and temperature sensing and offers pan/tilt, zoom color, and thermal camera video streaming capabilities. The vehicle is also able to carry a payload of about 50 pounds of batteries and can handle an additional 200 pounds of payload, whether for additional diagnostics, supplies, or clothing for those trapped in an effected area. GEMINI is remotely operated through a wireless connection and an onboard computer running a customized embedded control application, which directly communicates to all onboard components except for the audio and video systems. When line of sight is not possible, operators use a shockresistant fiber optic cable to ensure continuous functionality of the vehicle. This allows for direct local control of the vehicle, which streams collected data back to the operator for enhanced situational awareness. In addition, the vehicle incorporates safety features such as explosion proof housing to ensure safe electronic operations in hazardous gas or flooded environments; a four-channel video link and two-way audio to ensure located survivors can communicate with operators; and an MSHA-approved multi-gas sensor to monitor air quality.

42 ENGINEERING↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $ \$ $6B annually (at $ \$ $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year), and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE) missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

42 ENGINEERING↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗