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DOE OSTI2022

Mechanistic Insights and Rational Design of Ca-Doped CeO 2 Catalyst for Acetic Acid Ketonization

Carboxylic acid ketonization has recently gained significant attention to produce biomass-derived hydrocarbon fuels as it not only removes the highly reactive carboxylic functional group but also increases the size of the carbon chain. In this work, Ca-doped CeO 2 -based catalysts were investigated for acetic acid ketonization using a combined experimental and computational approach. Acetic acid conversion was performed across a range of temperatures including higher temperatures relevant to catalytic hot gas filtration (450 °C). Ca addition slightly decreases overall acetic acid ketonization reactivity yet stabilizes the catalyst at the higher temperatures necessary for catalytic hot gas filtration. From density functional theory calculations of the ketonization reaction mechanism, the C–C coupling and water formation steps are identified as two of the most energy-consuming steps on a CeO 2 surface with a proximal oxygen vacancy and the presence of a Ca dopant stabilizes the key intermediates. Calculations predict an optimal structure comprising three Ca ensembles to minimize the reaction free energies for C–C coupling and water formation steps. These findings provide a priori information to guide future experiments for ketonization catalyst design and development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Large Eddy Simulation of Externally Induced Ingress about an Axial Seal by Stator Vanes

Turbine inlet temperatures in advanced gas turbines could be as high as 2000 °C. To prevent ingress of this hot gas into the wheelspace between the stator and rotor disks, whose metals can only handle temperatures up to 850 °C, rim seals and sealing flows are used. This study examines the abilities of large eddy simulation (LES) based on the WALE subgrid model and Reynolds-averaged Navier–Stokes (RANS) based on the SST model in predicting ingress in a rotor–stator configuration with vanes but no blades, a configuration with experimental data for validation. Results were obtained for an operating condition, where the ratio of the external Reynolds number to the rotational Reynolds number is 0.538. At this operating condition, both LES and RANS were found to correctly predict the coefficient of pressure, C p , located downstream of the vanes and upstream of the seal, but only LES was able to correctly predict the sealing effectiveness. This shows C p by itself is inadequate in quantifying externally induced ingress. RANS was unable to predict the sealing effectiveness because it significantly under predicted the pressure drop in the hot gas path along the axial direction, especially about the seal region. This affected the pressure difference across the seal in the radial direction, which ultimately drives ingress.

42 ENGINEERING↗

DOE OSTI2024

High Temperature Additive Architectures for 65% Efficiency (Final Technical Report)

This project aimed to develop advanced high-temperature additive components that contribute towards the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. The objective was to leverage state-of-the-art additive manufacturing to develop an innovative stage 1 turbine nozzle (S1N) that can provide cooling flow savings while maintaining the component durability expected in today’s gas turbines. The program had two phases. Phase I was a conceptual phase for novel advanced cooling designs enabled by additive manufacturing, as well as proposals for validation. Phase II included execution of the Phase I conceptual design, including manufacturing of prototype hardware and validation within an environment that is similar to engine operation. During Phase I of the program, the team devised a concept to reduce cooling air usage. The cooling air used in the side walls is filmed out along the side walls, while the cooling air used in the airfoil is eventually directed to near-wall channels and exits holes along the airfoil trailing end. During this program, the team performed additive trials to analyze the geometric limitations of additive manufacturing. This helped the team understand minimum wall thicknesses, hole sizes, and cooling channel dimensions among other limits. Phase II of this program pushed GE Vernova beyond its previous experience of designing and manufacturing an additively manufactured hot gas path component. Modern hot gas path components utilize material chemistries that are traditionally hard to weld, such as cast Renè 108, and exhibit solidification cracking when additively manufactured using Direct Metal Laser Melting (DMLM). Note that AM108 is a powder form of Renè 108. A S1N with advanced cooling is larger and more complex than parts previously built by additive manufacturing and required new learnings to resolve risks around solidification cracking. Finally, the team validated the design in a combustion rig that replicated operation in a gas turbine. In order to properly quantify the benefits of the new additive design, a baseline was also tested in the rig and operated under the same conditions. In addition, an uncertainty analysis was done to quantify any sources of error that could impact the results. At the end of the validation effort, it was determined that the additive nozzle exceeded the 15% reduction in cooling flow goal even with the worst-case assumptions for uncertainty.

03 NATURAL GAS↗

DOE OSTI2025

Hubble Space Telescope Observations within the Sphere of Influence of the Powerful Supermassive Black Hole in PKS 0745-191

We present Space Telescope Imaging Spectrograph observations from the Hubble Space Telescope of the supermassive black hole (SMBH) at the center of PKS 0745-191, a brightest cluster galaxy (BCG) undergoing powerful radio-mode active galactic nucleus (AGN) feedback (P cav ~ 5 × 10 45 erg s -1 ). These high-resolution data offer the first spatially resolved map of gas dynamics within an SMBH's sphere of influence under such powerful feedback. Our results reveal the presence of highly chaotic, nondrotational ionized gas flows on subkiloparsec scales, in contrast to the more coherent flows observed on larger scales. While radio-mode feedback effectively thermalizes hot gas in galaxy clusters on kiloparsec scales, within the core, the hot gas flow may decouple, leading to a reduction in angular momentum and supplying ionized gas through cooling, which could enhance accretion onto the SMBH. This process could, in turn, lead to a self-regulating feedback loop. Compared to other BCGs with weaker radio-mode feedback, where rotation is more stable, intense feedback may lead to more chaotic flows, indicating a stronger coupling between jet activity and gas dynamics. Additionally, we observe a sharp increase in velocity dispersion near the nucleus, consistent with a very massive M BH ~ 1.5 × 10 10 M ⊙ SMBH. The density profile of the ionized gas is also notably flat, paralleling the profiles observed in X-ray gas around galaxies where the Bondi radius is resolved. These results provide valuable insights into the complex mechanisms driving galaxy evolution, highlighting the intricate relationship between SMBH fueling and AGN feedback within the host galaxy.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Particle Separator for Improved Flameless Pressurized Oxy-Combustion

The team of Southwest Research Institute® (SwRI®), ITEA, Electric Power Research Institute, Inc. (EPRI), and General Electric Global Research (GE) is advancing Flameless Pressurized Oxy-combustion (FPO), a novel coal technology. This effort seeks to develop a particle separator for the hot-gas stream leaving the FPO loop. In order to maximize the energy extracted from the cycle, the hot gas is put through a turbo-expander before flue-gas treatment. The particle separator designed under this project sought to operate at high temperature and with low-pressure drop, protecting the turbo-expander from erosion damage. The team engaged potential vendors for the test, developed plans for the pilot test loop modification, and refined requirements for the commercial turbo-expander.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Repairing High γ’ Hot Section Gas Turbine Components Using Advanced Manufacturing

This article describes the ability to use laser-blown powder deposition to repair high γ' IN-100 superalloy gas turbine components. The influence of various process conditions on the ability to make crack-free IN-100 deposits over surrogate high γ' alloys was investigated to identify cracking mechanisms in the deposit and heat-affected zones (HAZs). The various crack formation mechanisms, such as solidification cracking and liquation cracking, were evaluated using multiscale characterization and numerical simulation. The cracking in the deposit region was predominantly solidification cracking, while those observed in the HAZ were liquation cracking. The results showed that controlling thermally induced residual stresses is the key to eliminating cracking, and the optimum preheat temperature was determined. In conclusion, the results were then contrasted with those in published literature and an approach to effectively repair hot section parts was presented.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Signatures of large-scale cold fronts in the optically-selected merging cluster HSC J085024+001536

Abstract We represent a joint X-ray, weak-lensing, and optical analysis of the optically-selected merging cluster, HSC J085024+001536, from the Subaru HSC-SSP survey. Both the member galaxy density and the weak-lensing mass map show that the cluster is composed of south-east and north-west components. The two-dimensional weak-lensing analysis shows that the south-east component is the main cluster, and the sub-cluster and main cluster mass ratio is $0.32^{+0.75}_{-0.23}$. The north-west sub-cluster is offset by ∼700 kpc from the main cluster center, and their relative line-of-sight velocity is ∼1300 km s−1 from spectroscopic redshifts of member galaxies. The X-ray emission is concentrated around the main cluster, while the gas mass fraction within a sphere of 1′ radius of the sub-cluster is only $f_{\mathrm{gas}}=4.0^{+2.3}_{-3.3}\%$, indicating that the sub-cluster gas was stripped by ram pressure. An X-ray residual image shows three arc-like excess patterns, of which two are symmetrically located at ∼550 kpc from the X-ray morphological center, and the other is close to the X-ray core. The excess close to the sub-cluster has a cold-front feature where dense-cold gas and thin-hot gas contact. The two outer excesses are tangentially elongated about ∼450–650 kpc, suggesting that the cluster is merged with a non-zero impact parameter. Overall features revealed by the multi-wavelength datasets indicate that the cluster is at the second impact or later. Since the optically-defined merger catalog is unbiased for merger boost of the intracluster medium, X-ray follow-up observations will pave the way to understand merger physics at various phases.

Tanaka, Keigo↗

DOE OSTI2020

Gas Production from Hot Water Circulation through Hydraulic Fractures in Methane Hydrate-Bearing Sediments: THC-Coupled Simulation of Production Mechanisms

Methane hydrates, widely found in permafrost and deep marine sediments, have great potential as a future energy 6 source. Conventional production schemes perform poorly for challenging hydrate reservoirs with low permeability. We propose an 7 efficient production scheme by combining hydraulic fracturing from horizontal wells and hot water circulation through fractures. A 8 fully coupled thermo-hydro-chemical (THC) model is developed to simulate the key physical processes during gas production from 9 a hydrate reservoir representative of typical geological settings in Shenhu, South China Sea. We found that the gas production 10 process has two distinct stages divided by thermal breakthrough: a relatively short prebreakthrough stage and a postbreakthrough 11 stage yielding stable gas production. Heat advection along and near the hydraulic fracture dominates the prebreakthrough stage, 12 whereas conduction-driven thermal recovery in the volume around fractures dominates the postbreakthrough stage. We identified 13 that the steady-state injection temperature has a strong effect on the performance of the proposed scheme while the fluid mass 14 circulation rate has a moderate impact beyond a threshold. The proposed scheme proves to be efficient and robust over a range of 15 reservoir conditions with respect to initial hydrate saturation and intrinsic permeability, including their spatial heterogeneities, 16 thereby offering a promising solution for challenging reservoir conditions.

gas hydrate, fracture flow, gas production, numeri↗

DOE OSTI2021

The Polarized Image of a Synchrotron-emitting Ring of Gas Orbiting a Black Hole

Synchrotron radiation from hot gas near a black hole results in a polarized image. The image polarization is determined by effects including the orientation of the magnetic field in the emitting region, relativistic motion of the gas, strong gravitational lensing by the black hole, and parallel transport in the curved spacetime. We explore these effects using a simple model of an axisymmetric, equatorial accretion disk around a Schwarzschild black hole. By using an approximate expression for the null geodesics derived by Beloborodov and conservation of the Walker–Penrose constant, we provide analytic estimates for the image polarization. We test this model using currently favored general relativistic magnetohydrodynamic simulations of M87*, using ring parameters given by the simulations. For a subset of these with modest Faraday effects, we show that the ring model broadly reproduces the polarimetric image morphology. Our model also predicts the polarization evolution for compact flaring regions, such as those observed from Sgr A* with GRAVITY. With suitably chosen parameters, our simple model can reproduce the EVPA pattern and relative polarized intensity in Event Horizon Telescope images of M87*. Under the physically motivated assumption that the magnetic field trails the fluid velocity, this comparison is consistent with the clockwise rotation inferred from total intensity images.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Cluster environment quenches the star formation of low-mass satellite galaxies from the inside-out

ABSTRACT Environment plays a critical role in the star formation history of galaxies. Tidal and hydrodynamical stripping, prominent in cluster environment, can remove the peripheral gas of galaxies and star formation may thus be environmentally suppressed from the outside-in. We revisit the environmental dependence of the radial gradient of specific star formation rate (sSFR) profile. We probe the radial gradient by using the archival spectral indices D4000n and HδA measured from SDSS fibre spectra, to indicate central sSFR and the total sSFR from fitting the spectral energy distribution. Despite the low spatial resolution, the wealth of SDSS data allows to disentangle the dependences on stellar mass, sSFR, and environment. We find that low-mass satellite galaxies in the mass range $9\lt \mathrm{log}\, \mathcal {M}_{\star }/\mathcal {M}_{\odot }\lt 9.8$ on average quench in more inside-out pattern compared to isolated galaxies matched in mass, sSFR, and fibre coverage. This environmental effect is particularly strong for galaxies below the star formation main sequence, and peaks for those in the core of massive clusters where the phase-space diagram reveals clear links between the inside-out quenching and orbital properties. Our results suggest that both tidal and hydrodynamical interactions in cluster environment suppress the star formation of satellites mainly from the inside-out. As accreted gas of low angular momentum from hot gas haloes is an important source for replenishing central gas reservoir, we discuss how gas stripping in clusters may lead to starvation and cause inside-out quenching when the outer star-forming discs are not significantly affected.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Feedstock and Catalyst Impact on Bio-Oil Production and FCC Co-Processing to Fuels

NREL’s thermochemical biomass conversion research is focused on ex-situ upgrading of biomass fast-pyrolysis (FP) vapors as an efficient and economical route to completely biogenic pyrolysis-based fuel precursors, potential fuels, and value-added chemicals depending on catalyst choice and process conditions. In this approach, biomass vapors are generated via fast pyrolysis with destabilizing vapor components (char, inorganics, tar aerosols) removed by hot gas filtration to produce conditioned vapors more responsive to catalytic upgrading. A Davison Circulating Riser (DCR), a petroleum industry standard for fluidized catalytic cracking (FCC) catalyst evaluation, was coupled with a custom pyrolyzer system designed to produce consistent composition pyrolysis vapors as feed to the DCR. The coupled system is shown below (Figure 1). Pyrolysis vapors, derived from pure hardwood and softwood, were upgraded using commercially available and laboratory modified zeolite-based catalysts. Upgraded oils were analyzed via 31P and 13C NMR spectroscopy, GCxGC-TOF/MS, carbonyl and ultimate analysis (CHNO), and micro distillation to assess both oil chemistry and distillation behavior as they relate to catalyst and feedstock type for producing fungible hydrocarbon product liquids. Measured process parameters identified from technoeconomic process analysis included achieving oil oxygenate contents of 20% or less, carbon-conversion efficiencies of 30% or more, and catalyst coking rates of 10% or less. A proprietary modified zeolite catalyst from Johnson Matthey produced oils that met these requirements. Using the DCR equipped with a proprietary nozzle system, a second approach focused on reducing the carbon intensity of petroleum-derived hydrocarbon fuels by FCC co-processing these CFP oils with petroleum vacuum gas oil (VGO) to produce biogenic carbon containing fuels. The vapor-phase upgrading results demonstrated for the first time the feasibility of producing refinery-compatible hydrocarbon fuel intermediates entirely from biomass-derived fast-pyrolysis vapors using an industry-accepted DCR system for catalytic upgrading. The co-processing results demonstrated the feasibility of using CFP oils with VGO feeds in FCC refinery operations to produce biogenic carbon containing fuels.

bio-oil↗

DOE OSTI2024

Ne viii in the Warm-hot Circumgalactic Medium of FIRE Simulations and in Observations

Abstract The properties of warm-hot gas around ∼ L * galaxies can be studied with absorption lines from highly ionized metals. We predict Ne viii column densities from cosmological zoom-in simulations of halos with masses in ∼10 12 and ∼10 13 M ☉ from the Feedback in Realistic Environments (FIRE) project. Ne viii traces the volume-filling, virial-temperature gas in ∼10 12 M ☉ halos. In ∼10 13 M ☉ halos the Ne viii gas is clumpier, and biased toward the cooler part of the warm-hot phase. We compare the simulations to observations from the COS Absorption Survey of Baryon Harbors (or CASBaH) and COS Ultraviolet Baryon Survey (or CUBS). We show that when inferring halo masses from stellar masses to compare simulated and observed halos, it is important to account for the scatter in the stellar-mass–halo-mass relation, especially at M ⋆ ≳ 10 10.5 M ☉ . Median Ne viii columns in the fiducial FIRE-2 model are about as high as observed upper limits allow, while the simulations analyzed do not reproduce the highest observed columns. This suggests that the median Ne viii profiles predicted by the simulations are consistent with observations, but that the simulations may underpredict the scatter. We find similar agreement with analytical models that assume a product of the halo gas fraction and metallicity (relative to solar) ∼0.1, indicating that observations are consistent with plausible circumgalactic medium temperatures, metallicities, and gas masses. Variants of the FIRE simulations with a modified supernova feedback model and/or active galactic nuclei feedback included (as well as some other cosmological simulations from the literature) more systematically underpredict Ne viii columns. The circumgalactic Ne viii observations therefore provide valuable constraints on simulations that otherwise predict realistic galaxy properties.

Wijers, Nastasha A. (ORCID:0000000163747185)↗

DOE OSTI2020

Computational fluid dynamics analysis of char conversion in Sandia’s pressurized entrained flow reactor

Design and analysis of practical reactors utilizing solid feedstocks rely on reaction rate parameters that are typically generated in lab-scale reactors. Evaluation of the reaction rate information often relies on assumptions of uniform temperature, velocity, and species distributions in the reactor, in lieu of detailed measurements that provide local information. This assumption might be a source of substantial error, since reactor designs can impose significant inhomogeneities, leading to data misinterpretation. Spatially resolved reactor simulations help understand the key processes within the reactor and support the identification of severe variations of temperature, velocity, and species distributions. In this work, Sandia’s pressurized entrained flow reactor is modeled to identify inhomogeneities in the reaction zone. Tracer particles are tracked through the reactor to estimate the residence times and burnout ratio of introduced coal char particles in gasifying environments. The results reveal a complex mixing environment for the cool gas and particles entering the reactor along the centerline and the main high-speed hot gas reactor flow. Furthermore, the computational fluid dynamics (CFD) results show that flow asymmetries are introduced through the use of a horizontal gas pre-heating section that connects to the vertical reactor tube. Computed particle temperatures and residence times in the reactor differ substantially from the idealized plug flow conditions typically evoked in interpreting experimental measurements. Furthermore, experimental measurements and CFD analysis of heat flow through porous refractory insulation suggest that for the investigated conditions (1350 °C, <20 atm), the thermal conductivity of the insulation does not increase substantially with increasing pressure.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Novel Temperature Sensors and Wireless Telemetry for Active Condition Monitoring of Advanced Gas Turbines

The objective of the program is to develop and engine test hardware and software technologies that will enable active condition monitoring to be implemented on hot gas path turbine blades in large industrial gas turbines. The specific objectives are (1) to fabricate and install Smart Turbine Blades with thermally sprayed sensors and high temperature wireless telemetry systems in a gas turbine engine, (2) to integrate the component engine test data with remaining useful life (RUL) models and develop an approach for networking the component RUL data with Siemens' Power Diagnostics® engine monitoring system. These significant advances carried out in Phase 1 in temperature wide bandgap telemetry, along with new induced power driver and receiver geometry combined with an innovative approach to transmit digital data wirelessly will enable the opportunity to proceed with more technical innovation. The Phase 2 program focused on validation testing of sensor-wireless telemetry package in spin rig and advanced operation-based assessment (OBA) model utilizing artificial intelligence. Significant efforts were dedicated on the download of the technology onto components to be tested an actual gas turbine engine for full realization of active condition monitoring for Smart Turbine Blades.

03 NATURAL GAS↗

DOE OSTI2024

High Temperature Mechanical Behavior of Refractory Alloys with Digital Image Correlation

Gas turbine efficiency is typically limited by the maximum allowable temperature for components at the inlet side and in the hot gas flow. Refractory alloys and SiC/SiC ceramic-matrix composites (CMCs) are promising candidates for advancing operating temperatures beyond those of Ni-based alloys (>1200 °C). Refractory alloys are more suitable than SiC/SiC CMCs for dynamic components, due to the latter's low toughness and ductility. However, it is well known that refractory alloys suffer from poor oxidation behavior under service lifetimes and conditions, leading to embrittlement concerns. The ARPA-E ULTIMATE program has set out to combine new alloys with advanced coatings to mitigate oxidation/embrittlement effects, while increasing the mechanical performance benefits of refractory materials. Low oxygen (inert gas) or vacuum systems are needed to assess high temperature mechanical performance of developed alloys. To investigate the environmental sensitivity of candidate alloys and develop high temperature testing capabilities, four argon tensile frames were upgraded as well as a single vacuum system at Oak Ridge National Laboratory. Digital image correlation was incorporated into the vacuum frame allowing for surface strain determination and refined insight into thermomechanical response. Creep testing was performed at 1300 °C on two alloys, C-103 and MHC in vacuum and high purity argon environments. The Mo-based alloy showed less sensitivity to oxygen, indicating that testing in well-controlled argon environments may be suitable. The C-103 alloy demonstrated a stronger sensitivity to oxygen in the well-controlled argon environment, illustrating the need for the developed vacuum testing capabilities. “Small” 25 mm and “large” 76 mm MHC specimens showed comparable results in terms of strain rate during creep testing and ultimate tensile strength during tensile testing, suggesting the viability of smaller geometries that use less material of advanced developmental alloys.

Bell, Sam↗

DOE OSTI2022

Modeling of a 43 GHz microplasma within a photonic crystal

The electron density (n e ) and argon metastable density (1 s 5 ) of a 43GHz microplasma are obtained using the zero-dimensional plasma kinetics solver (ZDPlasKin®) for an incident power of 160 and 1000mW and argon pressures of 10–600Torr (1.3 ×10 3 to 8.0 × 10 4 Pa). These simulations are compared with previously published experimental data. To determine the self-consistent electric field in the modeled plasma, the three-dimensional millimeter wave fields are computed as a function of electron density using ANSYS EM19.2, HFSS®. This electromagnetic field model is coupled to ZDPlasKin such that any increase in the simulated plasma density correctly attenuates the simulated electric field within the microplasma. The electron density is found to be sensitive to argon gas temperature, so a two-zone temperature model was needed to obtain agreement with experimental measurements. The temperature in the central core of the microplasma was determined by a previous experimental study. That temperature was used as an input to the model for the simulation of volume recombination losses. The outer regions of the microplasma are assumed to be in equilibrium with the walls (300K). This second temperature was used in the model to determine diffusion losses. The modeled electron and metastable densities are of the order 10 20 and 10 18 m –3 , respectively. This is in good agreement with those measured experimentally as long as the two-zone temperature model is used. In the absence of a hot gas core, the modeled three-body recombination rates are excessive and the simulation severely under-predicts the electron density and over-estimates the metastable density. We conclude that the millimeter wave microplasma has a hot core (2500K at 600 Torr) that rarifies the argon gas and effectively reduces three-body recombination. Furthermore, this allows one to achieve high electron density on the order of 10 20 m –3 with only 100mW of wave power.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Segmented annular combustion system

An annular combustion system includes a fuel nozzle, a panel fuel injector including a fuel plenum and at least one premixing channel therein, an inner liner having a hot side surface and a cool side surface and an outer liner having a hot side surface and a cool side surface. The inner liner, the outer liner and the panel fuel injector partially define a hot gas path downstream from the fuel nozzle. The inner liner and/or the outer liner define a plurality of micro-channel cooling passages which is disposed between the hot side surface and cool side surface of the inner liner. Each micro-channel cooling passage of the first plurality of micro-channel cooling passages is in fluid communication with an inlet hole defined along the cool side surface of the respective liner and an outlet hole.

Berry, Jonathan Dwight↗

DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗