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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

In‐mold rheology and automated process control for injection molding of recycled polypropylene

Abstract Manufacturing plastic parts with secondary feedstocks has risen to the forefront of importance in recent years. However, the variation in molecular weight and rheology of secondary feedstock can lead to inconsistent part quality. This work evaluates the effectiveness of a novel closed‐loop adaptive process control system that adjusts nozzle pressure in response to in‐mold pressure data. Five different recycled polypropylene blends, with a broad distribution of flow properties, were evaluated to determine the effectiveness of the control system at reducing processing variation. The experimental results show that the process control strategy reduced the variation within the mold, as seen by in‐mold pressure curves and calculated in‐mold viscosity values. Additionally, the parameters that control the automated process adjustments were investigated, showing the importance of optimization. The analysis of the correlation between in‐mold rheology and mechanical properties showed a slight variation in the mechanical properties and parts weight with a coefficient of variation of under 5%. Overall, the results demonstrate the ability of pressure‐controlled molding and automated viscosity adjustment to reduce the variability when molding a secondary feedstock. Highlights Pressure‐controlled injection molding of recycled polypropylene. Automated closed‐loop adaptive process control methodology. Methodology resulted in a reduction in pressure variation during molding. Changes in mechanical properties and in‐mold viscosity were investigated. Results show the potential of pressure‐controlled molding at reducing variation.

Krantz, Joshua↗
DOE OSTI2020

Mechanistic modeling of CO 2 well leakage in a generic abandoned well through a bridge plug cement-casing gap

Both known and unmapped plugged and abandoned wells are potential leakage pathways for CO 2 from geologic carbon sequestration (GCS) sites. Although many abandoned wells have cement bridge plugs installed to prevent leakage, the seal between the cement and the inner casing wall is subject to failure. In this study, we carried out detailed T2Well simulations of cases of sudden non-Darcy flow of CO 2 and brine leakage up the gap between a cement plug and the inner steel casing wall that becomes a fully connected flow path during the post-injection period. The goal of our study was two-fold: (1) to understand the dynamics, rates, and the characteristic temporal signals associated with the onset of leakage through various gap-aperture sizes, and (2) to suggest potential monitoring strategies based on the findings. Simulation results show that the leakage of CO 2 and brine upward is transient with interesting phase interference behavior. Time-dependent oscillatory flows with varying pressure, temperature, and flow rates of CO 2 and brine show strong dependence on gap aperture. Phase-change and decompression lead to very low temperatures at the top of the well for gap apertures larger than 4 mm suggesting that remote thermal monitoring at the ground surface may be an effective way of monitoring even if well locations are not known a priori. Pressure in the well is also indicative of CO 2 leakage. The temporal patterns of changing temperature and pressure may be useful diagnostic signals for leakage detection. Finally, these transient leakage signals may provide information on the cause of leakage and/or characteristics of the flow path that could inform effective remediation design and execution approaches.

58 GEOSCIENCES↗
NASA NTRS2018

Fundamental Study of a 7-Element Fuel Injector Configuration for Gas Turbine Combustors - A Look at Cold Flow and Burning Measurements

Lean direct injection (LDI) is a combustion concept to reduce oxides of nitrogen (NOx) for next generation aircraft gas turbine engines. These newer engines have cycles that increase fuel efficiency through increased operating pressures, which increase combustor inlet temperatures. NOx formation rates increase with higher temperatures, and the LDI strategy is to avoid high temperature by staying fuel lean and away from stoichiometric burning. Thus, LDI relies on rapid and uniform fuel/air mixing. Additionally, in combustors for smaller core engines, the area and volume bring about mixing and time scale challenges not found in larger engines. As part of our parametric study in which we vary swirler angle and orientation and look at their effect on fluid mixing and combustion, we examine one configuration of a 7-point lean direct injector by looking at the non-combusting 2-D velocity field using PIV, and combusting system for chemical species using chemiluminescent imaging and flame spectroscopy. The circular 7-point array consists of axial swirlers, with the center 60° swirler surrounded by six 52° swirlers. The velocity results for this configuration show that the outer swirlers serve to isolate the center flow field near the injector exit. A recirculation zone forms downstream of the center swirler, but not behind the outer swirlers. The combusting results also show an isolated zone directly downstream of the center injector. The flame spectra show variation in speciation of combustion species such as OH*, C3*, CH*, and C2* as a function of position within the combustor.

lean direct injection↗
DOE OSTI2021

Regional Subsidence Analysis Through a Multi-Scale Modeling Framework Based on Breakage Mechanics

Although poroelastic models are often used to explain the delay between subsurface fluid depletion and ground subsidence, inelastic compaction involving permanent changes of rock microstructure may exacerbate hydro-mechanical coupling, thus influencing the interpretation of measurements and long-term forecasts. Here, a multi-scale modeling approach is discussed, which accounts for the inherent connection between rock microstructure, hydraulic conductivity, and pore compaction. A constitutive model built within the framework of breakage mechanics is proposed to link the hydraulic conductivity of granular rocks with inelastic deformations and changes in grading caused by injection-depletion cycles at stress levels far from yielding. The proposed model has been incorporated into large-scale simulation frameworks, thus enabling the spatiotemporal mapping of regional subsidence through a hybrid, semi-analytical approach. Numerical results based on this strategy show that the model allows isolating near-field and far-field effects into the computation of land subsidence and can generate forecasts for different modeling scenarios (e.g., elastic and inelastic compaction, constant permeability, and concurrent change of compressibility and permeability). In particular, examples of simulations for the case of the Groningen gas field are discussed, showing the model capabilities to use both field measurements and laboratory tests for the generation of reasonable subsidence maps, without expensive computational costs. Results indicate that ignoring coupled inelastic effects has major consequences on the predicted timescale of subsidence. Specifically, while all the model scenarios produced similar long-term ground settlements, those ignoring breakage-dependent permeability changes result in a variation of the temporal window of residual subsidence of the order of several decades.

58 GEOSCIENCES↗
DOE OSTI2024

Gain Stability of Hamamatsu R5912-MOD Photo-Multipliers at Low Temperature

The Photon Detection System is a crucial component of the ICARUS detector in the Short Baseline Neutrino (SBN) Program at Fermi National Accelerator Laboratory (FNAL). It consists of 360 Photo Multiplier Tubes (PMTs) 8” Hamamatsu R5912-MOD and, since June 2020, it has been operated at the liquid Argon cryogenic temperature. During these years, the PMTs have shown gain losses as an aging effect. Using a climatic chamber at the INFN Sezione di Catania, we confirmed a stable gain for a single PMT 8” Hamamatsu 5912-MOD when operated at room temperature, and a persistent gain loss at temperatures around -70°C, although far from the liquid Argon one. No gain recovery was obtained bringing the PMT back to room temperature. We suspect that dynode deterioration due to temperature gradient plays a significant role in this phenomenon. During our test, the PMT was illuminated by a 520 nm laser source and operated in current mode. The laser beam was split into two optical fibers, the first one transmitting light through Neutral Density filters and then diffusing it over the surface of the PMT photocathode. The other optical fiber was used for an independent reference measurement of the injected light via a bolometric photodetector. In this presentation, the main technical characteristics of the measurement system are shown together with preliminary results which need further investigation to elucidate the underlying mechanisms driving the gain loss and to propose new mitigation strategies.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

Mixing-Controlled CI Combustion and Fuel-Effects Research

This project is focused on developing advanced combustion strategies for mixing-controlled compressionignition (i.e., diesel-cycle) engines that are synergistic with renewable and/or unconventional fuels in a manner that enhances domestic energy security, economic competitiveness, and environmental quality. During this reporting period, the focus was on ducted fuel injection (DFI), a technology that differs from conventional diesel combustion (CDC) in that it involves injecting fuel along the axis of one or more small cylindrical ducts within the combustion chamber. Each duct performs a function similar to the tube on a Bunsen burner, helping to premix the fuel with the charge-gas before ignition, creating a stable flame that forms little to no soot. The purpose of the work conducted during Fiscal Year (FY) 2019 was to begin determining the extent to which the use of oxygenated fuels, when combined with DFI and charge-gas dilution, can simultaneously lower the soot and nitrogen-oxides (N0 x ) emissions from mixing-controlled compression-ignition engines, and what the corresponding impacts on other regulated emissions and efficiency are likely to be.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

ARC disruption physics and strategy

Commonwealth Fusion Systems (CFS) plans to operate a tokamak power plant called ARC in the early 2030s. Tokamak plasmas have stability limits that, if crossed, lead to a rapid termination of the plasma, referred to as a disruption. Disruptions pose a melt risk to the first wall resulting from thermal and non-thermal particle heat fluxes, and an electromagnetic loading risk on all metal components within the equilibrium coils. A comprehensive set of models is used herein to provide an assessment of both mitigated and unmitigated ARC disruption loads. A preliminary massive gas injection system is baselined and a runaway electron mitigation coil option is proposed to close possible gaps in the baseline. It is predicted that all ARC disruption loads are within a factor of 2 of the disruption loads in SPARC, a tokamak presently under construction by CFS, and therefore SPARC provides an opportunity to calibrate models, test solutions and inform the design of ARC. The goal for ARC is disruption-free operation, however, the pragmatic design target is to withstand one mitigated disruption per day, and to restart the plasma following mitigation in tens of seconds without interrupting the power output. Unmitigated disruptions must be rare, and experience with unmitigated disruption impacts in SPARC will better define what rare means. The implications of this strategy for plasma disruptivity and disruption prediction are discussed, and operating the ARC scenario on SPARC is expected to refine the ARC final design and operational plan.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Well–based monitoring of CO 2 geological sequestration operations in saline aquifers: Critical insights into key questions

Geological carbon sequestration in saline aquifers is one of the most promising strategies to help mitigate emissions of CO 2 to the atmosphere. Significant challenges in ensuring the security of the sequestration process rest in the evolution and expansion of the CO 2 plume in the subsurface. The ability to track the movement of the injected CO 2 poses another challenge. Critical questions related to the integrity of the sequestration operations in saline aquifers relate to plume characteristics that can we monitor using well-based variables. We addressed this and related questions using an integrated modeling framework through a numerical investigation of carbon sequestration in saline aquifers during long-term and post-injection periods. This modeling paradigm incorporates the effect of structural, geological, and petrophysical characteristics. That way, we can account for critical physicochemical processes, rock-fluid interactions, and lithology dependencies. The well fluid variables investigated include fluid composition, pH, fluid density, and ion activity. We learned that fluid property analytics and diagnostics can be powerful tools to estimate the movement of CO 2 and its storage in different trapping mechanisms. These analytics can help optimize operational aspects and simplify reservoir-scale models while still reflecting the complex nature of the CO 2 interactions underground and offering insights into plume evolution.

58 GEOSCIENCES↗
DOE OSTI2024

Lung and liver editing by lipid nanoparticle delivery of a stable CRISPR–Cas9 ribonucleoprotein

Lipid nanoparticle (LNP) delivery of clustered regularly interspaced short palindromic repeat (CRISPR) ribonucleoproteins (RNPs) could enable high-efficiency, low-toxicity and scalable in vivo genome editing if efficacious RNP–LNP complexes can be reliably produced. Here we engineer a thermostable Cas9 from Geobacillus stearothermophilus (GeoCas9) to generate iGeoCas9 variants capable of >100× more genome editing of cells and organs compared with the native GeoCas9 enzyme. Furthermore, iGeoCas9 RNP–LNP complexes edit a variety of cell types and induce homology-directed repair in cells receiving codelivered single-stranded DNA templates. Using tissue-selective LNP formulations, we observe genome-editing levels of 16-37% in the liver and lungs of reporter mice that receive single intravenous injections of iGeoCas9 RNP–LNPs. In addition, iGeoCas9 RNPs complexed to biodegradable LNPs edit the disease-causing SFTPC gene in lung tissue with 19% average efficiency, representing a major improvement over genome-editing levels observed previously using viral or nonviral delivery strategies. These results show that thermostable Cas9 RNP–LNP complexes can expand the therapeutic potential of genome editing.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2018

Realistic Covariance Generation for the GPM Spacecraft

A covariance realism process for NASA's Global Precipitation Measurement (GPM) spacecraft is detailed. The GPM spacecraft is in a low earth orbit, and performs collision avoidance maneuvers few times a year. Currently GPM is below the International Space Station (ISS). So, in addition to cataloged debris objects, GPM must contend with smallsat/cubesat objects that are deployed from the ISS. Both operational scenarios require complete knowledge of the expected GPM prediction errors as a function of time. In this study, we present a method for generating realistic predicted covariance that uses linear propagation of the covariance with the addition of process noise. Further analyses are presented for the process noise ''tuning'' that generates an inflation factor based on the observed error statistics of the predictive satellite trajectories when compared to the definitive ones. Different tuning strategies are considered and compared via a Goodness-of-Fit testing for the Gaussian properties of the scaled covariance. SpaceNav's realistic covariance generation approach takes into account the contribution of predicted maneuver errors in the increased propagation uncertainty. Corresponding maneuver uncertainty is injected into the state uncertainty, and is used within the collision avoidance process to determine the collision risk for close approach events that follow a maneuver. This is a critical step in the maneuver planning process that provides the satellite operator with an accurate quantification of the collision probability for planned maneuvers. Using this information, an informed decision can be made to proceed with a maneuver if the collision risk is acceptable. This approach is validated by Monte-Carlo simulations and results are presented.

spacecraft uncertainty propagation↗
DOE OSTI2023

Circular Reprocessing of Thermoset Polyurethane Foams

Thermoset polyurethane (PU) foams are widely used in industrial applications, but they cannot be recycled by conventional melt reprocessing because of their cross-linked structures. The introduction of carbamate exchange catalysts converts thermoset PU into covalent adaptable networks (CANs), which are amenable to reprocessing at elevated temperatures. However, this approach has produced solid PU films, which have fewer uses and lower commercial demand. In this work, simultaneous reprocessing and refoaming of thermoset PU foams is demonstrated by leveraging the melt-processability of PU CANs and allowing cell growth by gas generation in a twin-screw extruder. The optimal operating temperature of the refoaming process is determined through chemical, thermal, and structural analysis of PU foam extrudates. The foam-to-foam extrusion process produces controllable, continuous, and uniform foam structures, as characterized by cell diameter and cell number density. Low-density PU foams are obtained through a process simulating injection molding. The compression properties of reprocessed PU foam are compared with as-synthesized PU foam to demonstrate efficacy of the refoaming processes. These results demonstrate that PU foams can be prepared through recycling while maintaining microstructural and chemical integrity. In the future, this strategy may be applied to thermoset PU foams of various chemical compositions and shows promise for scalability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Novel strategies for modal-based structural material identification

Here, we present modal-based methods for model calibration in structural dynamics, and address several key challenges in the solution of gradient-based optimization problems with eigenvalues and eigenvectors, including the solution of singular Helmholtz problems encountered in sensitivity calculations, non-differentiable objective functions caused by mode swapping during optimization, and cases with repeated eigenvalues. Unlike previous literature that relied on direct solution of the eigenvector adjoint equations, we present a parallel iterative domain decomposition strategy (Adjoint Computation via Modal Superposition with Truncation Augmentation) for the solution of the singular Helmholtz problems. For problems with repeated eigenvalues we present a novel Mode Separation via Projection algorithm, and in order to address mode swapping between inverse iterations we present a novel Injective mode ordering metric. We present the implementation of these methods in a massively parallel finite element framework with the ability to use measured modal data to extract unknown structural model parameters from large complex problems. A series of increasingly complex numerical examples are presented that demonstrate the implementation and performance of the methods in a massively parallel finite element framework [7], [5], using gradient-based optimization techniques in the Rapid Optimization Library (ROL) [21].

36 MATERIALS SCIENCE↗
DOE OSTI2022

Scale-Up and Modeling Efforts Using an Omniphobic Surface Treatment for Mitigating Solids Deposition

Abstract Gas hydrates, waxes and asphaltenes represent some of the most significant flow assurance challenges, especially in subsea lines, where treatment options can be limited. Currently, complete avoidance is the primary strategy for hydrate management, while chemical or mechanical flushing/pigging may be utilized for other solids. Each system must also be treated with individualized solutions, as there have been no proved one-size-fits-all technologies demonstrated to date. As an alternative to constant chemical injection or thermodynamic controls such as insulation or heating, a robust omniphobic surface treatment material has been developed which has been shown in previous studies to significantly reduce the adhesion of flow assurance solids, resulting in lower risk for deposition and plugging of gas hydrates, waxes, and asphaltenes. As part of a Department of Energy study, laboratory scale tests were performed on a variety of apparatuses ranging from micromechanical force (micron scale) to laboratory flow loop testing (meter scale). While the results from these tests have been promising, there can be some disconnects between lab-scale observations and field-scale testing. Several factors can result in discrepancies between small-scale bench-top studies and deployment-scale efforts. These include flow conditions (Reynolds number, flow regime), chemistry (synthetic vs. crude oils, gas composition, and additives), physical differences (pipeline material, size, and geometry), etc. This work will describe the actions taken to better understand the deployment and performance of a material such as this omniphobic surface treatment in field scenarios, and to build confidence for deployment in a production scenario. These efforts include modeling field production scenarios using models developed from lab observations, application of the material to field-scale equipment to better understand application challenges, and expanded survivability and longevity testing. Understanding the bridge between laboratory testing and full-scale deployment allows for better technique and risk mitigation for field scale testing.

03 NATURAL GAS↗
NASA NTRS2015

Fundamental Study of a Single Point Lean Direct Injector. Part I: Effect of Air Swirler Angle and Injector Tip Location on Spray Characteristics

Lean direct injection (LDI) is a combustion concept to reduce oxides of nitrogen (NOx) for next generation aircraft gas turbine engines. These newer engines have cycles that increase fuel efficiency through increased operating pressures, which increase combustor inlet temperatures. NOx formation rates increase with higher temperatures; the LDI strategy avoids high temperature by staying fuel lean and away from stoichiometric burning. Thus, LDI relies on rapid and uniform fuel/air mixing. To understand this mixing process, a series of fundamental experiments are underway in the Combustion and Dynamics Facility at NASA Glenn Research Center. This first set of experiments examines cold flow (non-combusting) mixing using air and water. Using laser diagnostics, the effects of air swirler angle and injector tip location on the spray distribution, recirculation zone, and droplet size distribution are examined. Of the three swirler angles examined, 60 degrees is determined to have the most even spray distribution. The injector tip location primarily shifts the flow without changing the structure, unless the flow includes a recirculation zone. When a recirculation zone is present, minimum axial velocity decreases as the injector tip moves downstream towards the venturi exit; also the droplets become more uniform in size and angular distribution.

vortex↗
NASA NTRS2014

Fundamental Study of a Single Point Lean Direct Injector. Part I: Effect of Air Swirler Angle and Injector Tip Location on Spray Characteristics

Lean direct injection (LDI) is a combustion concept to reduce oxides of nitrogen (NOx) for next generation aircraft gas turbine engines. These newer engines have cycles that increase fuel efficiency through increased operating pressures, which increase combustor inlet temperatures. NOx formation rates increase with higher temperatures; the LDI strategy avoids high temperature by staying fuel lean and away from stoichiometric burning. Thus, LDI relies on rapid and uniform fuel/air mixing. To understand this mixing process, a series of fundamental experiments are underway in the Combustion and Dynamics Facility at NASA Glenn Research Center. This first set of experiments examines cold flow (non-combusting) mixing using air and water. Using laser diagnostics, the effects of air swirler angle and injector tip location on the spray distribution, recirculation zone, and droplet size distribution are examined. Of the three swirler angles examined, 60 deg is determined to have the most even spray distribution. The injector tip location primarily shifts the flow without changing the structure, unless the flow includes a recirculation zone. When a recirculation zone is present, minimum axial velocity decreases as the injector tip moves downstream towards the venturi exit; also the droplets become more uniform in size and angular distribution.

Tedder, Sarah A.↗
NASA NTRSDate not supplied

Artemis I: Test Flight Buys Down Risk for Humanity's Return to the Moon

The Artemis program successfully demonstrated its foundational deep space human transportation system during the Artemis I test flight in late 2022. This bold mission put the Artemis program on a course to accomplish increasingly complex missions to return humans to the Moon and to prepare for Mars and other destinations. The Artemis I uncrewed mission tested the Space Launch System (SLS) rocket and the Orion spacecraft using the ground processing, launch and recovery services provided by the Exploration Ground Systems (EGS) program at the Kennedy Space Center (KSC). The Artemis team accomplished key mission priorities that deliberately bought down risk for upcoming crewed missions as part of a build-up flight test strategy. The Artemis I mission priorities were 1) demonstrate Orion heatshield at lunar re-entry conditions; 2) operate systems in flight environment; and 3) retrieve the spacecraft. The successful performance and demonstration of these primary mission objectives from lift-off thru orbital insertion, translunar injection, outbound transit towards the Moon, entry into lunar orbit, coast in the lunar Distant Retrograde Orbit (DRO), exit from lunar orbit, transit back to Earth, atmospheric re-entry, descent, splashdown and recovery successfully showed that NASA has a foundational deep space transportation capability in place for human class missions. In addition to the primary mission objectives, a set of scientific payloads, approved Flight Test Objectives (FTOs) and Development Flight Test Objectives (DFTOs) were incorporated into the nominal mission plan and were designated as secondary, or priority 4, and were considered “bonus objectives” in terms of crewed flight risk buydown. During the mission, the team found itself in a position where it was comfortable achieving even more content than originally planned. As a result, DFTOs were added during the mission to further buy down risk to later crewed test flights. This paper presents an overview of the Artemis I test flight, including mission priorities and key test objectives, the launch campaign and as-flown mission profile, test objectives accomplished over the course of the 25.5- day mission, and implications to the crewed Artemis II and later test flight missions.

Artemis↗
DOE OSTI2021

EV Hosting Capacity Analysis on Distribution Grids: Preprint

Increasing electric vehicle (EV) charging loads can increase the magnitude and duration of conventional peaks in demand profiles and even shift them significantly, causing operational violations in the distribution grid. It is important to develop tools to quantify the impacts of injecting large number of EV charging loads and determine the available capacity of the existing distribution feeder for the safe operation of the grid. Such tools would enable utilities to better prepare for grid operations in the near future while exploring the impact and effectiveness of strategies such as peak pricing and smart charging in managing these loads. This paper evaluates the hosting capacity of some real-world feeders to accommodate EV charging loads, including extreme fast-charging (xFC) options.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

ASSESSING FUEL PROPERTY EFFECTS ON CAVITATION AND EROSION PROPENSITY USING A COMPUTATIONAL FUEL SCREENING TOOL

To advance compression ignition combustion strategies, researchers have evaluated fuel property effects and their impact on achieving higher efficiencies and lower emissions levels relative to current capabilities. Within the Department of Energy's Co-Optima initiative, there has been a recent focus on understanding the influence of fuel properties on fuel injection performance. To help identify candidate fuels that can meet desired injector performance metrics, a computational fuel screening tool is under development that can link fuel properties with the tendency of a given fuel to cavitate and lead to cavitation-induced erosion. In the initial development of this tool, five liquid fuel properties were selected to represent candidate fuels, namely density, viscosity, vapor pressure, surface tension, and heat of vaporization. A design of experiments methodology was employed to generate a set of pseudo fuel cases, which can represent the main effects and interactions among the fuel properties and be related to cavitation erosion predictions. Large eddy simulations were performed using a mixture modeling approach to predict the cavitation and erosion propensity of these pseudo-fuels in terms of the mean fuel vapor mole fraction and stored impact energy from repeated cloud collapse events. The low order regression models generated from this study revealed the importance of liquid fuel density on cavitation formation, whereas liquid viscosity was found to have a strong negative correlation with erosion severity. The surrogate models were then used in the fuel screening tool to rank the cavitation and erosion tendency of four candidate single-component fuels: methyl decanoate, isooctane, ethanol and n-dodecane. While the fuel screening tool was not able to quantitatively predict the cavitation and erosion response metrics, the tool was able to accurately rank the relative cavitation and erosion propensity of the four fuels. Overall, ethanol and iso-octane were observed to produce the highest levels of cavitation and erosion, respectively.

cavitation-induced erosion↗