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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Background-Oriented Schlieren Velocimetry of Helium Coolant Flow in Additively Manufactured Channels

High-pressure helium gas cooling is an attractive solution for thermal management of the fusion blanket first wall, as this coolant is chemically and neutronically inert and separable from hydrogenic species. However, due to the low thermal mass of helium, geometric optimization of these channels is required to provide sufficient cooling at manageable flow rates and pumping burdens. Increasingly, analysis and optimization of these coolant channels rely on computational fluid dynamics (CFD) simulations, and these require relevant experimental data for turbulence model validation. Toward this end, a high-pressure helium gas flow visualization system has been employed to image the flow of helium in flow channels with one-sided heating, mimicking the blanket first wall environment. Flow of helium at 4 MPa pressure and flow rates up to 68 g/s (Reynolds number 57 000) is supplied to rectangular channel test sections, with uniform heating applied to the bottom wall of the channel at heat fluxes varied between roughly 50 and 130 kW/m2. A high-speed camera is used to image index of refraction (IOR) gradients in the fluid via background-oriented schlieren (BOS), and temperature and pressure instrumentation are used to characterize thermal-hydraulic performance of each channel. Cross correlation of time-resolved BOS images is then used to calculate time-averaged 2-D helium velocity fields. Flow in additively manufactured (AM) channels is examined in this manner, including both featureless channels and those containing baffling as a heat transfer enhancement. The flow distribution seen in the featureless case differs significantly from that seen in prior simulations, whereas the flow in the baffled case shows the predicted behavior of flow forced along the heated wall. This augmented flow distribution is seen to increase the heat transfer coefficient in the baffled test section. Here, strategies are discussed for ongoing and future validation of these simulations, with the aim of model deployment for blanket cooling design and optimization.

Additive manufacturing↗
DOE OSTI2025

Using 3D Measurements from MRI to Improve VVUQ

Magnetic resonance velocimetry (MRV) is a diagnostic that can measure 3D, three-component turbulent velocity fields in arbitrarily complex flow configurations. The approach uses magnetic resonance imaging (MRI), which is a system commonly available in radiology departments or medical research centers. MRV acquires signal from hydrogen protons in water channel flows. Despite the obvious utility of the measurements for investigating a variety of flows, comparisons with computational fluid dynamic (CFD) simulations largely retain traditional metrics, comparing velocity profiles and planes at discrete regions within the flow rather than using the 3D nature of the measured field. In this effort, MRV was conducted in a simple water channel with six spanwise-centered periodic obstacles roughly shaped as cubes. At a fully turbulent Reynolds number of 15,000, the channel includes two flows: a main streamwise flow and, in the wake of the second obstacle, an injected flow oriented perpendicular to the streamwise flow. The flow geometry includes partial obstacles on the side walls and is inherently 3D because of the interaction of the two streams and the wake features, making the flow challenging to completely measure with traditional optical techniques. Aside from line profiles and planar comparisons, two 3D metrics are used to compare the data with a steady Reynolds-averaged Navier–Stokes (RANS) simulation result. A brief discussion about the comparison is provided, including comments about uncertainty.

Benson, Mike [ORNL] (ORCID:000000023210116X)↗
DOE OSTI2024

Development of prechamber enabled mixing-controlled combustion strategy for ultra-low methane emissions from lean burn natural gas engines

This numerical study explores the optimization of Prechamber Enabled Mixing-Controlled Combustion (PC-MCC) using natural gas in heavy-duty engines, aiming to enhance combustion efficiency to minimize methane slip and NOx emissions. The approach involves a prechamber ignition system, distinct from conventional spark ignition (SI) systems, to initiate combustion of direct injected natural gas. By leveraging the robust ignition characteristics of the prechamber, the PC-MCC method demonstrates significant potential in achieving efficient combustion akin to diesel engines but with lower greenhouse gas emissions. The research evaluates the effects of various geometric and operational parameters on the combustion process and emissions, including prechamber volume, nozzle diameter, direct injector (DI) geometry, and engine operating strategies. Computational Fluid Dynamics (CFD) simulations are utilized, focusing on a heavy-duty, single-cylinder engine modeled after the Caterpillar C9.3B engine. Key findings indicate that a prechamber volume of 3 cc, coupled with a nozzle diameter of 2.75 mm for two prechamber holes, strikes an optimal balance between combustion efficiency and emissions reduction. This configuration ensures robust combustion across a range of operating conditions while maintaining methane slip within targeted limits. Further investigation into DI geometry shows the significance of the injector umbrella angle and nozzle diameter in shaping the fuel-air mixing and combustion dynamics. An umbrella angle of 130° and a nozzle diameter of 300 microns are identified as optimal, promoting rapid and efficient combustion with minimized methane and NOx emissions. The study also investigates the impact of injection timing and pressure, highlighting their roles in controlling combustion timing and influencing emissions levels. Advanced injection timing is found to be crucial in achieving the desired low methane slip, whereas retarded injection timing assists to reduce NOx emissions while having a slight increase in methane emissions. Operating strategies incorporating various levels of Exhaust Gas Recirculation (EGR) are assessed for their effectiveness in further reducing emissions. The research demonstrates that a judicious combination of internal hot EGR and careful calibration of DI pressure and SOI timing can achieve significant reductions in NOx emissions while keeping methane slip under control. Specifically, an internal EGR level of 15%–25%, combined with DI pressures of 200–300 bar and injection timings at or after top dead center, is recommended. These findings contribute valuable insights into the development of advanced combustion techniques for natural gas engines, offering a viable pathway to reduce methane slip without compromising engine efficiency or performance. The PC-MCC system presents a promising solution for the future of heavy-duty natural gas engine technology to reduce methane emissions.

Nsaif, Osama↗
DOE OSTI2024

Carbon Capture through Membranes - Leveraging Multiphysics Modeling, Dimensional Analysis and Machine Learning to Scale up and Optimize Devices and Processes for Decarbonization

We study the separation performance using membrane modules through dimensional analysis (DA). We formulate the main process equations to identify relevant dimensionless numbers inherent in the physics. In particular, we identify that the critical step in the separation process is mass transfer through the selective layer. Remarkably, the dimensionless feed flow (DFfeed) emerges as a crucial factor in describing this process. Not only does DFfeed directly appear in the governing equations, but it also holds a physical significance associated with the time scales for the mass transfer across the feed side and through the selective layer. Regarding the output performance variables, we consider the recovery, stage cut, productivity and purity. In this context, we profit from experimental data and CFD simulations to evaluate the separation performance of the modules when varying the input flowrate, the scale of the module, and the CO2 permeance. These datasets enable us to establish correlations between performance metrics and the dimensionless feed flow (DFfeed). Using simple power functions of DFfeed, we obtain R2 coefficients exceeding 0.99, indicating the accuracy of the correlations built in the present work. In the future, we wish to use DA to understand key transport mechanisms, predict and control module performance, and challenge the universality of these findings by testing various gas separations across different membrane modules beyond our case study.

Pedrozo, Hector A.↗
DOE OSTI2024

Modeling and Scaling up of Membrane Modules Leveraging Dimensional Analysis

In the current analysis, we study the separation performance using membrane modules through dimensional analysis (DA). We formulate the main process equations to identify relevant dimensionless numbers inherent in the physics. In particular, we identify that the critical step in the separation process is mass transfer through the selective layer. Remarkably, the dimensionless feed flow (DFfeed) emerges as a crucial factor in describing this process. Not only does DFfeed directly appear in the governing equations, but it also holds a physical significance associated with the time scales for the mass transfer across the feed side and through the selective layer. Regarding the output performance variables, we consider the recovery, stage cut, productivity and purity. In this context, we profit from experimental data and CFD simulations to evaluate the separation performance of the modules when varying the input flowrate, the scale of the module, and the CO2 permeance. These datasets enable us to establish correlations between performance metrics and the dimensionless feed flow. Using simple power functions of DFfeed, we obtain R2 coefficients exceeding 0.99, indicating the accuracy of the correlations built in the present work. In the future, we wish to use DA to understand key transport mechanisms, predict and control module performance, and challenge the universality of these findings by testing various gas separations across different membrane modules beyond our case study.

Pedrozo, Hector A.↗
DOE OSTI2024

Computational Analysis of the Effect of Structured Packing Design on Absorption Column Hydrodynamics for Post-Combustion Carbon Capture Applications

Solvent based post-combustion carbon capture technologies have a potential for reducing carbon emissions from fossil-fuel-fired power plants and industrial sources where CO2 emissions are inherently harder to mitigate, such as steel or cement industries. A prominent technology to achieve this is by retrofitting absorption columns to the existing infrastructure. While these systems have been among the less costly alternatives for carbon capture, they still impose a considerable energy penalty to the operation of power plants or industrial facilities. The optimization of CO2 capture rate in solvent-based absorption process is complex as it depends on several factors including CO2 solubility, solvent reaction kinetics and temperature effects on the solubility, reaction rates, surface tension, and thermophysical properties of the solvent and the flue gas. The overall heat and mass transfer also depends on the hydrodynamics, which in turn, is affected by the packing geometry. In the current work, we systematically quantify the effects the design of the structured packing has on the column hydrodynamics, by performing detailed CFD simulations for different geometrical configurations and operating conditions. We then obtain relationships between the key hydrodynamic metrics, such as liquid holdup, interfacial area, wetted area, and pressure drop to the parameters defining the packing geometries and identify new more effective packing designs for the given operating conditions.

Shah, Yash Girish↗
DOE OSTI2025

INTEGRATE – Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements

The INTEGRATE (Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements) project developed a new inverse-design capability for the aerodynamic design of wind turbine rotors using invertible neural networks. Training data was obtained from improved turbulence and transition models for RANS and hybrid RANS/LES solvers with machine-learned physics-based data-augmented corrections and then using the resulting neural-network(s) augmented RANS model to run thousands of 2-D and 3-D CFD simulations.

17 WIND ENERGY↗
DOE OSTI2026

Plasma-Assisted Pre-Chamber Ignition System for Highly Dilute Stoichiometric Heavy-Duty Natural Gas Engines (Final Technical Report)

This project explored advanced ignition technologies to significantly enhance efficiency and reduce operating costs for heavy-duty natural gas engines operating at stoichiometric conditions, while meeting ultra-low NOx emission standards. The main goal was to develop and validate a plasma-assisted pre-chamber ignition system that could deliver at least a 2% increase in brake thermal efficiency (BTE) and a 4% decrease in total cost of ownership (TCO) compared to a typical multi-cylinder engine with three-way catalyst aftertreatment, ensuring compatibility with the expected 2027 EPA/CARB regulations. In the first half of the project, the research team concentrated on developing and testing plasma-assisted pre-chamber ignition using nanosecond pulsed discharges. Extensive experiments were conducted in an optically accessible rapid-compression and expansion machine, a constant-volume chamber, and an optical single-cylinder engine. Experiments were coupled with CFD simulations. The work produced unique insights into pre-chamber flame formation, jet ignition, dilution effects, and flame quenching at pressures, temperatures, and dilution levels relevant to engines. Although plasma-assisted ignition showed promise in controlled lab settings, the research also identified fundamental and practical challenges when applying this technology to real engine conditions. Midway through the project, a crucial pivot was made, guided by three key findings. First, the power electronics required for nanosecond plasma discharges were found to be too costly for commercial use, undermining the project’s cost-of-ownership goals. Second, nanosecond plasma ignition was highly sensitive to turbulent flow in the pre-chamber, resulting in lower ignition reliability than traditional spark under engine-like conditions. Third, achieving a truly diffuse low-temperature plasma at high pressures near top dead center was not possible, reducing the anticipated chemical enhancement benefits. These results collectively suggested that continuing with plasma-assisted ignition was unlikely to meet both efficiency and cost objectives. In response, the project shifted focus to a more realistic approach: enhancing traditional spark-based pre-chamber ignition with significantly less spark energy. Using insights gained earlier in the project, the team redesigned the pre-chamber to maintain high dilution tolerance and quick combustion, even with lower ignition energy. Testing confirmed that with optimized pre-chamber design and combustion timing, a lower-energy spark could reliably ignite highly diluted stoichiometric mixtures, reduce burn time, and boost thermal efficiency. Final engine testing and techno-economic analysis verified that this revised approach successfully achieved the project goals. The optimized pre-chamber ignition system provided over a 2% increase in calculated brake thermal efficiency compared to the baseline engine. Notably, the lower ignition energy and simplified hardware reduced component stress, extended maintenance intervals, and lowered the total cost of ownership. When used with stoichiometric operation and traditional three-way aftertreatment, the system remained compatible with near-zero NOx emissions targets without increasing cost or complexity in the emissions control system. In summary, although the project deviated from its initial plasma-assisted ignition idea, the work produced a more practical and commercially viable solution. The results show that precisely optimized, low-energy pre-chamber spark ignition can significantly improve efficiency and reduce overall ownership costs for heavy-duty natural gas engines. This directly aligns with DOE goals for cleaner, more efficient, and cost-effective transportation technologies.

03 NATURAL GAS↗
DOE OSTI2025

Outflow Boundary Conditions for Turbine-Integrated Rotating Detonation Combustors

This study examines outflow boundary conditions (BCs) in computational fluid dynamics (CFD) simulations of a transition duct with and without guide vanes that converts supersonic flow exiting a rotating detonation combustor (RDC) to subsonic flow to drive a turbine. Since the flow exiting the transition duct has swirling shock waves with significant spatial and temporal variations in pressure, temperature, and Mach number, imposing proper BCs poses a challenge. To ensure all swirling shock waves exit the transition duct without creating non-physical reflected waves at its outlet, this study examined three outflow BCs: (1) the average pressure imposed at the duct’s outlet, (2) a nonreflecting BC (NRBC) with a specified average pressure imposed at the duct’s outlet, (3) the average pressure imposed at the outlet of an extension duct made up of a buffer layer and a sponge layer. This study is based on the three-dimensional, unsteady density-weighted-ensemble-averaged continuity, Navier–Stokes, and energy equations for a thermally perfect gas closed by the realizable k–ε model and “enhanced” wall functions. The results obtained show that imposing an average pressure at the transition duct’s outlet produces spurious waves that degrade the physical meaningfulness of the solution. When the NRBC was applied, swirling shock waves exited the duct’s outlet without creating spurious waves. However, its usage requires the gas to be thermally, as well as calorically, perfect, which this study shows could be a concern. By imposing the average pressure at the outlet of an extension duct, the gas does not need to be calorically perfect. The results obtained show the effects of the sponge layer’s length and coarsening ratio on damping nonuniformities in non-physical reflected waves to ensure the flow exiting the transition duct’s outlet can do so as if there are no boundaries present and has the desired average pressure—even though the BC is applied at the extension duct’s outlet.

gas turbines↗
DOE OSTI2026

Investigation of Flux Spreading in a Light-Trapping, Planar-Cavity Receiver for Enclosed Solar Particle Heating

Concentrating solar thermal power (CSP) technology development has recently focused on increasing the operating temperatures to accommodate high efficiency power cycles and thermochemical processes. Inert solid particles as heat transfer media enable solar receivers to operate above 700 degrees Celsius resulting in increased system thermal efficiency compared to the conventional molten salt based CSP system. An open-cavity falling-particle solar receiver that can efficiently heat particles by direct heating from concentrated solar radiation faces challenges with large particle losses from wind and unable to support thermochemical reactions. A light-trapping, planar cavity reiver (LTPCR) where particles are indirectly heated can significantly minimize the particle losses during the operation, support thermochemical reactions, and offer scalability potential. The LTPCR features an array of vertical planar receiver/absorber panels arranged within a cavity configuration. Concentrated solar radiation from heliostats is focused onto the receiver walls, where heat is indirectly transferred to solid particles flowing inside the receiver channels. Heat transfer occurs through direct contact between the receiver panel walls and particles, and can be enhanced by fluidizing particles with air. This fluidization increases particle-wall contact and extends particle residence time, maximizing heat transfer efficiency. The unique vertical planar receiver structure originated from a near-blackbody tubular light absorber, effectively distributing the incoming solar beam spread across the panel walls and trapping light. This flux spreading effect, driven by cosine projection, converts high incident solar flux into a lower, more uniform heat flux on the panel walls. This redistribution enhances heat transfer efficiency between particle-wall or reaction gases-wall, while preventing localized overheating of the receiver panel. Indirect planar cavity solar receivers completely separate solid particles from the ambient environment that can greatly reduce the thermal losses in heated particles resulting in high efficiency at high temperatures above 700 degrees Celsius. This design ensures no particle losses to the environment during the operation while open-cavity designs can experience significant particle losses from wind. An experimental investigation was conducted to observe flux spreading on the receiver panel wall. A lab-scale prototype planar receiver, fabricated using Haynes 230 alloy, was tested under direct concentrated solar radiation using the high-flux solar furnace (HFSF) facility at NREL. The experiment was performed under normal peak radiative heat fluxes ranging from 800 to 1900 kW/m2. A temperature distribution on the panel wall was measured using a thermal imaging camera (FLIR A 6600). To prevent overheating at the receiver front tip, prism-shaped heat shields (Zircar UNIFROM C1) were placed in front of the receiver, and their influence on flux spreading was also studied. Absorbed flux distribution on the panel wall was modeled using SolTrace. The total solar power and flux distributions delivered from HFSF were determined based on the heliostat mirror optical properties, direct normal irradiance (DNI) on the on-sun testing days, peak flux measurement during the on-sun testing, and shutter/attenuator settings Due to the large incident angles of the solar beam on the panel wall, the angular optical properties of Haynes 230 alloy and Zircar heat shields were incorporated into the model. This flux distribution model was then integrated into a computational fluid dynamics (CFD) simulation to predict the receiver panel wall temperature, which was compared with the experimental measurements. Both prediction and measurements identified a temperature hotspot at the backside of the panel, indicating that the incident solar beam can fully reach to the rear of the receiver. The heat shields positioned at the front of the receiver effectively reduced the excessive temperature rise at the receiver front tip. Overall, the temperature was well distributed over the panel wall, with a minor hotspot at the back of the receiver. The model slightly overpredicted the temperature, possibly due to discrepancies in optical properties of the panel and an underprediction of thermal loss in the receiver. The advancement of the particle LTPCR offers a viable alternative to open-cavity receivers by addressing particle loss issues. Additionally, it presents a pathway for enabling solar thermochemical processes, extending CSP technology beyond power generation to fuel and chemical production.

14 SOLAR ENERGY↗
NASA NTRS1990

Supersonic flameholding by attached oblique shock waves

The object of this investigation was to explore various regimes of shock-induced combustion that may occur as a result of supersonic flow of a reactive gas mixture past a simple compression ramp or wedge. Attention was confined to combinations of wedge angles, fuel-air mixture ratios and freestream velocities that permit the resulting oblique shock or oblique detonation wave to remain attached. Computational fluid dynamic (CFD) simulations, both inviscid and viscous, were performed and analyzed in order to investigate two modes of compression ramp flameholding; namely, complete oblique detonation wave (ODW) and shock-induced combustion. In addition, the possibility of flame persistence or hysteresis was explored. It was preliminarily concluded that inclusion of viscous effects may be essential to accurately predict the occurrence of the various flameholding modes.

Fort, James A.↗
NASA NTRS1989

A turbulent boundary layer at low Reynolds number with adverse pressure gradient

The evolution of a low Re(theta) turbulent boundary layer in an adverse pressure gradient (APG) is studied for comparison with CFD simulations by Spalart (1988). A short region of favorable pressure gradient is applied first to establish a self-preserving layer which is a suitable initial condition for the simulations. The APG is then applied rapidly such that Beta(x) of about 2 for Re(theta) of about 1500.

Watmuff, J. H.↗
NASA NTRS1991

Aerothermodynamic environment predictions in support of the Aeroassist Flight Experiment

A computational fluid dynamic (CFD) simulation has been made of the flow past an Aeroassist Flight Experiment (AFE) aerobrake model with a payload and sting. The simulation involves solving the complete Navier-Stokes equations in three dimensions. Comparisons with data taken in a Mach 10 wind tunnel test are made and agreement is shown to be very good. Points of comparison include the aerobrake surface pressure and heat transfer rate, the sting surface streamlines, and the sting heat transfer rate. The dependence of the solution on the grid is also explored. Finally, predictions are made for conditions which correspond to a hypersonic shock tunnel force and moment test to be carried out later this year.

Fay, John F.↗
NASA NTRS1992

Modeling of solid/porous wall boundary conditions for the validation of computational fluid dynamics codes

A computational study has been undertaken to investigate method of modeling solid and porous wall boundary conditions in computational fluid dynamics (CFD) codes. The procedure utilizes experimental measurements at the walls to develop a flow field solution based on the method of singularities. This flow field solution is then imposed as a boundary condition in a CFD simulation of the internal flow field. The effectiveness of this method in describing the boundary conditions at the wind tunnel walls using only sparse experimental measurements has been investigated. Position and refinement of experimental measurement locations required to describe porous wall boundary conditions has also been considered.

Beutner, Thomas J.↗
NASA NTRS1991

Aerobrake aerothermodynamic environment predictions in support of the Aeroassist Flight Experiment

A computational fluid dynamic (CFD) simulation of the flow past an Aeroassist Flight Experiment (AFE) aerobrake under wind tunnel test conditions has been made. The Navier-Stokes equations in three dimensions were solved numerically using a finite-volume, implicit approach. Comparisons with experimental data include surface pressures and heat transfer rates and aerodynamic coefficients. Agreement with experiment is shown to be excellent. The dependence of the solution on the computational grid is explored. The present work is preliminary to simulation of the flow past the AFE under flight conditions, which at present cannot be duplicated with ground-based experimental facilities.

Fay, John F.↗
NASA NTRS1992

A summary of the computational fluid dynamics analysis of the hypersonic flights of Pegasus

A computational fluid dynamics (CFD) analysis of the hypersonic flights of the NASA's Pegasus launch vehicle was carried out using the PARC code. The flight data included heat transfer rates and sparse pressure coefficients primarily in the fillet region of the vehicle. Since the CFD simulations did not account for ablation at the vehicle surface, the test heat transfer results were obtained for the low Mach number simulations; as the Mach number was increased, the ablative effects at the vehicle surface became more apparent and contributed to the error.

Fricker, Darren↗
NASA NTRS1992

Analysis of film cooling in rocket nozzles

Progress during the reporting period is summarized. Analysis of film cooling in rocket nozzles by computational fluid dynamics (CFD) computer codes is desirable for two reasons. First, it allows prediction of resulting flow fields within the rocket nozzle, in particular the interaction of the coolant boundary layer with the main flow. This facilitates evaluation of potential cooling configurations with regard to total thrust, etc., before construction and testing of any prototype. Secondly, CFD simulation of film cooling allows for assessment of the effectiveness of the proposed cooling in limiting nozzle wall temperature rises. This latter objective is the focus of the current work. The desired objective is to use the Finite Difference Navier Stokes (FDNS) code to predict wall heat fluxes or wall temperatures in rocket nozzles. As prior work has revealed that the FDNS code is deficient in the thermal modeling of boundary conditions, the first step is to correct these deficiencies in the FDNS code. Next, these changes must be tested against available data. Finally, the code will be used to model film cooling of a particular rocket nozzle. The third task of this research, using the modified code to compute the flow of hot gases through a nozzle, is described.

Woodbury, Keith A.↗
NASA NTRS1993

Determination of solid/porous wall boundary conditions from wind tunnel data for computational fluid dynamics codes

A computational and experimental study has been undertaken to investigate methods of modeling solid and porous wall boundary conditions in CFD codes. The procedure utilizes experimental measurements at the walls to develop a flow field solution based on the method of singularities. This flow field solution is then imposed as a boundary condition in a CFD simulation of the internal flow field. The effectiveness of this method in describing the boundary conditions at the wind tunnel walls using only sparse experimental measurements has been investigated. Verification of the approach using computational studies has been carried out using an incompressible flow solver. The current work demonstrates this technique for low speed flows and compares the result with experimental data obtained from a heavily instrumented variable porosity test section. Position and refinement of experimental measurements required to describe porous wall boundary conditions has also been considered for application to other porous wall wind tunnels.

Beutner, Thomas J.↗