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DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence F - Raw Data

Sequence F: Downwind High Cone (F) This test sequence used a downwind, rigid turbine with an 18° cone angle. The wind speed ranged from 10 m/s to 20 m/s. Excessive inertial loading due to the high cone angle prevented operation at lower wind speeds. Yaw angles of ±20° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link was replaced with a shorter bar so the load cell was not installed during this test. However, the teeter link load cell channel was flagged as not applicable by setting the measured values in the data file to -99999.99 N.

17 WIND ENERGY↗

DOE OSTI2021

A MEMS Nanopositioner With Integrated Tip for Scanning Tunneling Microscopy

Not provided.

Engineering↗

DOE OSTI2022

Investigation of the effects of passive pre-chamber nozzle pattern and ignition system on engine performance and emissions

The impact of passive pre-chamber (PC) internal volume, nozzle hole pattern (i.e. with and without a central axial nozzle), and PC igniter plug type on performance and emissions was investigated in an optically accessible, single-cylinder, gasoline research engine. The two PC igniter plugs investigated were a conventional inductive coil spark plug and a nanosecond repetitively pulsed (NRP) plasma discharge system previously demonstrated to accelerate early flame propagation. The baseline PC design featured a funnel shaped internal volume with a PC tip that contained six radial nozzles and a larger central axial nozzle. Two additional PC tip geometries were evaluated where either the baseline internal volume was increased or the axial nozzle was removed and the radial nozzle diameters were increased. A sweep of charge equivalence ratios ( ϕ) from nearly stoichiometric to the lean limit was performed for a fixed engine speed (1300 revolutions per minute), and engine load (3.5 bar gross indicated mean effective pressure). Time-resolved PC and main chamber (MC) pressure data as well as MC emissions data were collected to analyze engine performance and emissions characteristics. Combustion in the MC was further investigated using high-speed excited methylidyne radical (CH*) chemiluminescence imaging. Collected results highlighted that while all PC tips and ignition systems exhibited similar performance and emissions down to ϕ = 0.8, relevant differences in thermal efficiency and emissions for leaner charge mixtures were observed, with the results highly dependent on the nozzle pattern and ignition system. Major deviations were correlated to preferential de-pressurization of the PC through the axial nozzle for lean conditions that was not observed for mixture conditions closer to stoichiometric. Results show that a combination of radial and axial nozzle patterns in the PC extended lean-stability limits at the low-load condition evaluated. Further benefits were observed with the use of NRP ignition systems due to faster combustion within the PC volume provided that the volume was sufficiently large.

Di Sabatino, Francesco↗

DOE OSTI2022

Diffraction and thermal effect of a Bessel-Gaussian laser for Ag nanoparticle deposition

Nanoparticles are known to sinter at much lower temperatures than the corresponding bulk or micro size particles. A laser-assisted sintering process is considered in this study to sinter Ag nanoparticles by dispensing Ag paste onto an indium tin oxide-coated Si substrate. The Gaussian beam of a CO 2 laser source is propagated through axicon and biconvex lenses, and the resulting hollow beam is focused on the Ag paste with a hollow parabolic mirror. A Bessel-Gaussian irradiance distribution is obtained at the focal plane of the parabolic mirror due to the interference of the hollow laser cone. The Fresnel diffraction approximation is considered to determine the phasor of the laser and an analytical approach is implemented to calculate the irradiance distribution of the Bessel-Gaussian beam. This irradiance distribution is utilized as a heat source in a heat conduction model and the temperature distribution is analyzed for thin Ag films formed during the laser sintering of Ag nanoparticles. An analytical expression is obtained for the temperature distribution by solving the heat conduction equation using Fourier transform for finite media. The widths of the deposited Ag lines are predicted from the temperature profiles and the model predictions compare well with the experimental results. The isotherms are found to be geometrically noncongruent with convex and concave tips depending on the locally maximum and minimum irradiances of the Bessel-Gaussian beam, respectively. The convex and concave tips, however, appear in the same isotherm for sufficiently high substrate speed relative to the laser beam.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2024

CT584 Is Not a Protective Vaccine Antigen against Respiratory Chlamydial Challenge in Mice

Background: Chlamydia trachomatis is the most prevalent bacterial sexually transmitted pathogen in humans worldwide. Since chlamydial infection is largely asymptomatic with the potential for serious complications, a preventative vaccine is likely the most viable long-term answer to this public health threat. Cell-free protein synthesis (CFPS) utilizes the cellular protein manufacturing machinery decoupled from the requirement for maintaining cellular viability, offering the potential for flexible, rapid, and decentralized production of recombinant protein vaccine antigens. Methods: Here, we use CFPS to produce the full-length putative chlamydial type three secretion system (T3SS) needle-tip protein, CT584, for evaluation as a vaccine antigen in mouse models. High-speed atomic force microscopy (HS-AFM) (RIBM, Tsukuba, Japan) imaging and computer simulations confirm that CFPS-produced CT584 retains a native-like structure prior to immunization. Female mice were primed with CT584 adjuvanted with CpG-1826 intranasally (i.n.) or CpG-1826 + Montanide ISA 720 intramuscularly (i.m.), followed four weeks later by an i.m. boost before respiratory challenge with 10 4 inclusion forming units (IFU) of Chlamydia muridarum. Results: Immunization with CT584 generated robust antibody responses but weak cell-mediated immunity and failed to protect against i.n. challenge as demonstrated by body weight loss, increased lung weights, and the presence of high numbers of IFUs in the lungs. Conclusion: While CT584 was not a protective vaccine candidate, the speed and flexibility with which CFPS can be used to produce other potential chlamydial antigens make it an attractive technique for antigen production.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

Critical instability at moving keyhole tip generates porosity in laser melting

Laser powder bed fusion is a dominant metal 3D printing technology. However, porosity defects remain a challenge for fatigue-sensitive applications. Some porosity is associated with deep and narrow vapor depressions called keyholes, which occur under high-power, low–scan speed laser melting conditions. High-speed x-ray imaging enables operando observation of the detailed formation process of pores in Ti-6Al-4V caused by a critical instability at the keyhole tip. We found that the boundary of the keyhole porosity regime in power-velocity space is sharp and smooth, varying only slightly between the bare plate and powder bed. The critical keyhole instability generates acoustic waves in the melt pool that provide additional yet vital driving force for the pores near the keyhole tip to move away from the keyhole and become trapped as defects.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence M - Raw Data

Sequence M: Transition Fixed (P) Test sequence M used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 15 m/s. Yaw angles ranged from 0° to 90°. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read –99999.99. Zigzag tape was installed near the leading edge of the instrumented blade on both the upper and lower surfaces as described in Appendix K. In addition to the standard 30-second campaigns, yaw sweeps were done at 7 m/s and 10 m/s. These 90-second campaigns were collected while the yaw drive rotated the turbine 90° at a rate of 1°/s. The file names for these campaigns use the letter designation, followed by two digits for wind speed, followed by YSU, followed by 00.

17 WIND ENERGY↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence V - Raw Data

Sequence V: Tip Plate (F) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 25 m/s, and the yaw angle was held at 0°. The blade pitch angle was 3°. The rotor rotated at 72 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read -99999.99. The standard tip blocks were replaced with a tip plate to simulate the effect of an undeployed tip-mounted aerodynamic brake as shown in Appendix A. Note that the blade radius was not changed during post-processing so the pressure tap locations are at the same radial location, but the reference to 30% represents 30% of 5.029 m, not 4.943 m. Throughout this report, references to the blade span are made for the 5.029- m radius, not the 4.943-m radius.

17 WIND ENERGY↗

DOE OSTI2023

Insights Into Lightning K‐Leader Initiation and Development From Three Dimensional Broadband Interferometric Observations

Abstract We report detailed observations of K‐leaders and the activity between them with the three‐dimensional Broadband Interferometric Mapping and Polarization system (BIMAP‐3D) at Los Alamos National Laboratory. It is found that K‐leaders have a general propagation trend of initial acceleration and then gradual deceleration, and the corresponding very high frequency (VHF) radiation power is exponentially correlated with the leader speed. Based on the 3D development and simultaneous electric field change measurement, some simple K‐leaders can be modeled with time‐evolving point charges at the propagating leader tip and at the stationary origin. We found that the charge magnitude increases during the initial acceleration stage and stays relatively constant for the rest of the development. K‐leaders are observed to interact with other branches; the branches affect the leader's propagation speed, and may affect the charge transfer. After the occurrence of a K‐leader, VHF emissions are quenched for several milliseconds. VHF sources then reappear in an impulsive and scattered manner as “twinkling,” and these sources are found not uniquely on the so‐called needles, but also on the main channel. These twinkling sources start near the apparent positive leader tip, and extend back toward the direction of the flash origin at about 10 5 m/s, while the apparent positive tip continues to extend forward at about 10 4 m/s. The twinkling extending toward the direction of flash origin appears to initiate the following K‐leader, although it may be interrupted by a K‐leader along a different branch, or simply die out without more K‐leader activity.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence E - Raw Data

Sequence E: Yaw Releases (P) This test sequence used a downwind, rigid turbine with a 3.4° cone angle. The wind speeds ranged from 7 m/s to 17 m/s. Initial yaw angles of ±90° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. The turbine was positioned at each specified yaw angle. A 30- second data set was collected with the yaw brake engaged. These points used a letter for the last digit beginning with A and proceeding through the alphabet as repeat points were needed. These points were plotted and compared to ascertain the functionality of the instrumentation. The files ending in numbers beginning with 0 and increasing with each repetition represent yaw release points. Once the fixed-position yaw test was complete, the yaw drive was engaged to hold the turbine. The yaw brake was released, and the yaw drive was disabled allowing the turbine to yaw freely. The yaw drive was disabled about 5 seconds into the campaign, and the turbine was allowed to yaw freely for the rest of the 30-second duration. When the yaw drive is disabled, no torque is applied to the motor, and the inertia and yawing force of the nacelle and rotor overcomes the friction and inertia of the yaw gear and motor. The yaw releases were repeated five times at each condition. Four additional campaigns were collected to determine the turbine’s natural yaw error by releasing the brake at 0° yaw error. These file names use the E designation, followed by two digits for wind speed, followed by XXXX, followed by the repetition digit.

17 WIND ENERGY↗

DOE OSTI2022

Physics-informed Bayesian machine learning case study: Integral blade rotors

This paper provides a physics-informed Bayesian machine learning (PIBML) description and case study. The PIBML approach applies three physics-based models to establish the initial beliefs before testing to determine the probability of milling stability (or prior). These include: receptance coupling substructure analysis (RCSA) prediction for the tool tip frequency response functions; finite element software prediction of the mechanistic force model coefficients; and a spindle speed-dependent power law model for process damping. Testing was then performed to identify optimal stable machining conditions using an expected improvement in material removal rate criterion. The prior probability of stability was updated using the test results to determine the posterior probability of stability. The test results were compared to the parameter recommendations provided by the endmill manufacturer. A demonstration integral blade rotor was machined at the optimal stable machining conditions for 304 stainless steel and 6061-T6 aluminum. Finally, the disagreement between manufacturer recommendations and milling performance in both materials tested emphasizes the need for broad implementation of PIBML approaches to increase machining productivity and efficiency.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 4 - Raw Data

Sequence 4: Static Pressure Calibration (P) This test sequence used a downwind, teetered turbine with a 3.4° cone angle. The wind speed ranged from 5 m/s to 25 m/s. Yaw angles of 0° to 30° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. A static pitot probe was installed on a boom 2.3 m upwind of the nacelle at hub height and connected to the reference side of the Mensor digital differential pressure transducer through the pneumatic rotary coupling. This provided the reference pressure for all blade-mounted pressure transducers, as opposed to the NASA atmospheric pressure reference that was used for all other test sequences. This simulates the pressure system connections used in field measurements where the static pressure was unknown.

17 WIND ENERGY↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 8 - Raw Data

Sequences 8 and 9: Downwind Sonics (F,P) and Downwind Sonics Parked (P) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 25 m/s. Yaw angles of 0° to 60° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM during Sequence 8, but it was parked during Sequence 9. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read -99999.99. Sonic anemometers were mounted on a strut downwind of the turbine. The strut was mounted to the T-frame, which was rotated to align the anemometers aft of the 9% and 49% radius locations at hub height. Because of this configuration, the tunnel balance data are considered invalid. Sequence 9 was designed to compare the downwind sonic anemometer readings with the upwind sonic anemometers without interference from the turbine. The rotor was parked with the instrumented blade at 0° azimuth. All pressure measurements obtained in Sequence 9 are invalid because sufficient time for temperature stabilization did not occur, thus all associated data values were flagged as not applicable by setting the measured values in the data file to 0.0000 Pa. This test is further described in Appendix G.

17 WIND ENERGY↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 9 - Raw Data

17 WIND ENERGY↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence P - Raw Data

Sequence P: Wake Flow Visualization, Upwind (P) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 15 m/s. Yaw angles of 0° to –60° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. The aluminum blade tip designed to contain a smoke generator was installed, and counterweights were installed in the non-instrumented blade tip to compensate. The turbine was positioned at the appropriate yaw angle, and the smoke generator was ignited remotely. The campaign duration was 3 minutes for all tests except P1000000, which was 2 minutes. The file name convention was the standard format except for P10000A0, which indicated a 3° pitch angle. File P1000000 used a 12° pitch angle. After these two campaigns were collected, it was determined that all subsequent data should be collected with a 3° pitch angle. Pressure data were not acquired during this sequence, so all associated data values were flagged as not applicable by setting the measured values in the data file to 0.000 Pa. Corresponding pressure data are available from Sequence H for the 3° pitch angle test points. Flow visualization data obtained from wall- and ceiling-mounted video cameras were recorded to videotape. The camera locations and calibration procedures are described in Appendix J.

17 WIND ENERGY↗

DOE OSTI2021

Land-based wind turbines with flexible rail-transportable blades – Part 1: Conceptual design and aeroservoelastic performance

This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. One of the five blade designs is segmented and serves as a benchmark to the state of the art in industry. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway for increasing the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m s –1 and a pitch-to-stall shutdown strategy to minimize blade tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

17 WIND ENERGY↗

DOE OSTI2023

New insights on wind turbine wakes from large‐eddy simulation: Wake contraction, dual nature, and temperature effects

Abstract Large‐eddy simulation (LES) has been adopted to study wind turbine wakes because it can capture fine‐scale details of turbulent wind flows and interactions with wind turbines. Here, we use the LES version of the Weather Research and Forecasting (WRF) model with an actuator disk model to gain insights on several wake effects that have been traditionally difficult to measure. The first finding is that the wake has a “dual nature,” meaning that the wind speed deficit behaves differently from the added turbulent kinetic energy (TKE) and the two are not co‐located in space. For example, the wind speed deficit peaks at hub height and reaches the ground within 8D (D is the rotor diameter), but added TKE peaks near the rotor tip and generally remains aloft. Second, temperature changes near the ground are driven by the added TKE in the rotor area and by atmospheric stability. The combination of these two factors determines the sign and intensity of the vertical heat flux divergence below the rotor, with convergence and warming associated with stable conditions and weak divergence and modest cooling with unstable conditions. Third, wakes do not expand indefinitely, as suggested by similarity theory applied to the wind speed deficit, but eventually stop expanding and actually contract, at different rates depending on atmospheric stability. The implication of these findings is that, in order to study wakes, it is not sufficient to focus on wind speed deficit alone, because TKE is also important and yet behaves differently from the wind speed deficit.

17 WIND ENERGY↗

DOE OSTI2020

Combined visualisation of cavitation and vortical structures in a real-size optical diesel injector

A high-speed flow visualisation set-up comprising of combined diffuse backlight illumination (DBI) and schlieren imaging has been developed to illustrate the highly transient, two-phase flow arising in a real-size optical fuel injector. The different illumination nature of the two techniques, diffuse and parallel light respectively, allows for the capturing of refractive-index gradients due to the presence of both interfaces and density gradients within the orifice. Hence, the onset of cavitation and secondary-flow motion within the sac and injector hole can be concurrently visualised. Experiments were conducted utilising a diesel injector fitted with a single-hole transparent tip (ECN spray D) at injection pressures of 700–900 bar and ambient pressures in the range of 1–20 bar. High-speed DBI images obtained at 100,000 fps revealed that the orifice, due to its tapered layout, is mildly cavitating with relatively constant cavity sheets arising mainly in regions of manufacturing imperfections. Nevertheless, schlieren images obtained at the same frame rate demonstrated that a multitude of vortices with short lifetimes arise at different scales in the sac and nozzle regions during the entire duration of the injection cycle but the vortices do not necessarily result in phase change. The magnitude and exact location of coherent vortical structures have a measurable influence on the dynamics of the spray emerging downstream the injector outlet, leading to distinct differences in the variation of its cone angle depending on the injection and ambient pressures examined.

42 ENGINEERING↗