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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Global Evaluation of Process Conditions and Wave Modes in a Rotating Detonation Engine

Rotating Detonation Engines (RDEs) show significant promise for enhancing the efficiency of gas turbine engines while maintaining low 𝑁𝑂𝑥 emissions. This work investigates the predictability of wave modes in a water-cooled RDE under varying operational conditions. Experimental data comprising over 6,700 samples was collected, including parameters such as flow rates, temperatures, pressures, and equivalence ratios. A machine learning approach using the XGBoost library was used to build a multi-class classifier, predicting wave modes based on these inputs. The model achieved a high accuracy of 97%, demonstrating that wave modes are not random but deterministic based on the process conditions. SHAP analysis was used to identify the most influential parameters affecting wave mode prediction. The results show that for the water-cooled NETL RDE, wave mode is determinant and predictable based on the process parameters.

Weber, Justin [NETL] (ORCID:0000000218487035)↗
DOE OSTI2021

Simulation of Premixed and Partially Premixed Jet-in-Crossflow Flames at High Pressure

In this paper, we explore the operational map of a lean axial-staged combustor of premixed and partially premixed reacting jet-in-crossflow flames at high -pressure (5 atm). This study attempts to expand the data to relatively high pressure and could significantly aid scaling to real gas turbine engine conditions at 20–30 atm. High-speed camera, particle image velocimetry (PIV), CH* chemiluminescence, temperature, and pressure measurements were taken and processed to allow accurate reconstruction of six operating points relative to computational fluid dynamics (CFD) simulations under minimal adjustments. Variation of lean main stage (φ = 0.575 and 0.73) and rich jet (φ = 1.1, 4, and 8) equivalence ratio has been investigated for a four mm axial jet. The fully premixed flames were found to be controlled by the crossflow temperature before ignition and the crossflow oxygen content during combustion. Analysis of flame shape and position for the partially premixed operating points describes a lee stabilized as well as a more unsteady windward flame branch. Adjustment of added jet fuel and crossflow temperature along with its corresponding oxygen level is required to attain a compact flame body. Here, the risk of delaying combustion progress is significantly increased at a richer jet φ = 8 and an overshooting, spatially divided flame was attained with a main stage φ = 0.73. Control toward a compact flame body is critical to allow combustion at reasonable reaction rate.

03 NATURAL GAS↗
DOE OSTI2025

Novel Design and Fabrication of a High Frequency Transient Heat Flux Sensor for Use in an RDE

Rotating detonation engine (RDE) combustion systems have been a topic of interest in the pressure gain combustion community for their benefits over traditional gas turbine engine combustors. However, cooling requirements for these engines are significantly higher and less predictable than non-detonating engines. To understand the high-speed heat transfer dynamics inside an RDE, a novel, high-frequency heat flux gage is presented. This study aims to design a robust, single-sided sensor that can withstand the high temperature and harsh environment of an RDE for extended durations. Sensor bench testing is performed using a hot plate as a heat source, and the sensor response is compared to a finite-element analysis (FEA) model. The sensor response is then tested inside a water-cooled RDE and the wall heat flux is compared to calorimetry data.

rotating detonation engines↗
DOE OSTI2025

Novel Design and Fabrication of a High Frequency Transient Heat Flux Sensor for Use in an RDE

Rotating detonation engine (RDE) combustion systems have been a topic of interest in the pressure gain combustion community for their benefits over traditional gas turbine engine combustors. However, cooling requirements for these engines are significantly higher and less predictable than non-detonating engines. To understand the high-speed heat transfer dynamics inside an RDE, a novel, high-frequency heat flux gage is presented. This study aims to design a robust, single-sided sensor that can withstand the high temperature and harsh environment of an RDE for extended durations. Sensor bench testing is performed using a hot plate as a heat source, and the sensor response is compared to a finite-element analysis (FEA) model. The sensor response is then tested inside a water-cooled RDE and the wall heat flux is compared to calorimetry data.

rotating detonation engines↗
DOE OSTI2020

Performance Characterization of a Natural Gas–Air Rotating Detonation Engine

An experimental study of a rotating detonation engine (RDE) operating with natural gas and air at elevated chamber pressures and air preheat temperatures was conducted to quantify its performance at conditions representative of land-based power generation gas turbine engines. Here, the thrust produced by the combustor was measured to characterize its work output potential. High-frequency pressure transducers and broadband chemiluminescence measurements of the flame provided information about the wave structure and dynamics. Analysis of common performance metrics demonstrated the necessity of normalizing any RDE performance parameter by the driving system potential, typically the reactant manifold pressure. Application of a thermodynamic performance model to a generic RDE identified the area ratio between the RDE exhaust and injection throats as the primary parameter affecting delivered pressure gain. The model was further applied to draw comparison with experimental measurements of net pressure gain for identical flow conditions. Only one of the two tested injector configurations followed the predicted trends, suggesting that performance of the second was governed by physical processes other than the reactant thermodynamics. Although an absolute pressure gain was not demonstrated, it is promising that the natural gas–air RDE delivered up to 90% of the theoretical performance.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Operability of a Natural Gas–Air Rotating Detonation Engine

A combustor was developed to operate with natural gas and air as the primary propellants at elevated chamber pressures and air preheat temperatures representative of land-based power generation gas turbine engines. Detonation dynamics were studied to characterize the operability of rotating detonation-based pressure gain combustion systems for this application. Measurements of chamber wave dynamics were performed using high-frequency pressure transducers and high-speed imaging of broadband combustion chemiluminescence. The rotating detonation engine was tested with two injector configurations across a broad range of mass flux (200–500 kg/m 2 /s), equivalence ratio (0.85–1.2), and oxygen mass fraction (23.2–35%) conditions to determine the effect of operating parameters on the propagation of detonation waves in the combustor. Wave propagation speeds of up to 70% of the mixture Chapman–Jouguet detonation velocity and chamber pressure fluctuations greater than 4 times the mean chamber pressure were observed. Supplementing the air with additional oxygen, varying the equivalence ratio, and enriching the fuel with hydrogen revealed that combustor operability is sensitive to the chemical kinetics of the propellant mixture. Comparing the operational trends of the two injector configurations suggests that one design mixes the incoming propellants more effectively. Although most test conditions exhibited counter-rotating detonation waves within the chamber, the injector design with superior mixing characteristics was able to support single-wave propagation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine

Modifying fossil-fueled industrial gas turbines to utilize low or zero-carbon fuels, such as hydrogen or hydrogen-natural gas blends, is a complex endeavor. The successful implementation of this technology hinges on three key design criteria: (1) developing new fuel injectors capable of efficiently burning alternative fuels, (2) ensuring manufacturability to meet cost and time-to-market goals, and (3) achieving component durability in the demanding environment of an operating gas turbine. Additive manufacturing (AM) accelerates product development, yet concerns persist regarding the durability of parts with rough AM surfaces. A fully experimental approach to quantify the fatigue performance of rough AM microstructures is both costly and labor-intensive. To address this, ORNL and Solar Turbines Incorporated (Solar) employed a crystal plasticity finite element (CPFE) model to identify the factors influencing AM surface fatigue behavior. These CPFE findings, combined with targeted experimental data, were used to develop a computationally efficient surrogate model suitable for assessing the lifespan of gas turbine engine components.

08 HYDROGEN↗
DOE OSTI2024

Abstract for CRADA between National Energy Technology Laboratory and TOPTICA Photonics, Inc.

The National Energy Technology Laboratory (NETL) and Toptica Photonics (Participant) will collaborate to demonstrate the application of a frequency-comb laser (dual-comb spectroscopy) in an optically accessible rotating detonation engine (RDE). RDEs are a next-generation energy conversion technology which are well-suited to hydrogen usage and have the potential to significantly increase the efficiency of gas turbine engine power cycles. However, critical information is needed about the high temperature and pressure detonation wave, which represents an extremely challenging diagnostic environment. Dual-comb spectroscopy can be used to characterize the pressure-broadened IR absorption features at MHz rates, providing information not possible with conventional tunable diode laser (TDL) technologies. This collaboration will, for the first time, demonstrate application of dual-comb spectroscopy within the combustion annulus of a hydrogen-air RDE. If successful, the data generated will help to accelerate commercialization of RDE technologies in support of decarbonizing our nation’s energy sector.

08 HYDROGEN↗
DOE OSTI2024

Design, Analysis, and Experimental Testing of Hydrogen Lean Direct Injection Nozzles at Elevated Pressure

Abstract There are many challenges of commissioning a hydrogen combustor into future gas turbine engines; especially regarding achieving emissions goals. Previously, Escudero et al. and Tran et al. conducted a study to adapt the liquid fuel Lean Direct Injection (LDI) concept from Jet-A to gaseous natural gas-hydrogen blends and pure hydrogen [1], [2]. Experimental data was collected at atmospheric conditions using a Box Behnken design of experiments. The design of experiments suggested that biasing the air split in favor of the inner air circuit and increasing the swirl strength of this inner air passage resulted in improved NOx emissions, while the inverse was true for stability, which was quantified by studying the lean blowoff point (LBO) [1], [2]. The trends revealed by the original experiment [1], [2] provided a design direction for further iterations of the experimental hardware. The study presented herein describes the further investigation of such LDI injectors through experimental methods and computational fluid dynamic (CFD) simulations at atmospheric conditions, which were used to identify potential flow behaviors driving enhanced emissions performance. Further evaluation of select injectors from both studies was then conducted at elevated pressures up to 6 atmospheres. The results from both experiments are presented in this study, which include flame observations, emissions measurements, and operational challenges. NOx emissions results are reported on a volume basis in ppmvd corrected to 15% O2 and corrected for fuel. A predictive model for relating NOx emissions to test conditions at atmospheric conditions show high significance to adiabatic flame temperature while little to no significance to fuel composition for the best performing configurations. The results illustrate the connection between atmospheric testing and testing elevated pressures. The design direction indicated by the initial tests and CFD results in promising configurations for implementation into a Multi-point LDI array.

08 HYDROGEN↗
DOE OSTI2023

High-density SSiC 3D-printed Lattices for Compact HTHP Aero-engine Recuperators

The proposed project utilizes advanced ceramic-based 3D-printing technology to develop light, low-cost, ultra-compact, high-temperature high-pressure (HTHP) heat exchangers (HX) for the harsh oxidizing environment of aircraft gas-turbine engines. Typical 3D printing technologies (powder bed or lithographic techniques) cannot produce large high-density, monolithic ceramic material with intricate internal features and channels required for high-temperature, high-pressure recuperators. Furthermore, typical 3D printing technologies are not yet economical for large high-density components. A high-density material is required for hermeticity, high-temperature strength, and oxidation, corrosion, and wear resistance. The team has invented an extrusion-based additive manufacturing technology (referred to as robocasting) and developed processing techniques to tailor composition and rheological mix properties for rapid 3D printing of high-density alumina and SiC parts. The goal of the proposed project is to use robocasting technology to demonstrate commercializable high-density 3D-printed ceramic HX modules with high durability and quality, thereby reducing the risk of thermo-mechanical failure under extreme environments. In addition, the proposed project improves the quality of the ceramic 3D-printing process over a large printed area and HTHP operating conditions. Ceramic 3D printing technology also provides a means to create advanced topologies that are unobtainable with conventional manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Preheating and premixing effects on NO x emissions in a high-pressure axially staged combustor

NO x emissions remain a primary concern for modern and future gas turbines, particularly as we progress towards a net-zero carbon future. It is critical to identify novel strategies to mitigate environmental pollutants for both modern turbines operated on natural gas and future turbines projected to use carbon-free fuels (such as hydrogen). In the current study, NO x emissions of a reacting methane-air jet in a vitiated crossflow are experimentally investigated in a model axially staged combustor at 5 atm. The combustion products from the main stage combustor flow into the axial stage at temperatures ranging from 1580 to 1650 °C. The axial stage contains a reacting jet in crossflow, which provides an overall temperature rise ranging from 50 to 220 °C to generate exit temperatures similar to gas turbine engines. The focus of this paper is to explore the effects of flame liftoff and ignition timescales on the NO x contribution of this secondary jet. This is done by varying the premixed level and preheat temperature of the axial jet. The effects are explored at different momentum flux ratios (J), jet equivalence ratios (φ jet ), exit temperatures (T exit ), and main stage (headend) temperatures (T HE ). High-speed CH* chemiluminescence imaging is employed for each test case to determine the flame stabilization point. For a given temperature rise and combustor exit temperature, an increase in ignition delay was observed with a decrease in jet temperature. This provided a NO x benefit, particularly for jets that are injected at or close to an ignitable mixture fraction. Similarly, the coaxial injector caused a significant ignition delay compared to the fully premixed injector; this also led to a NO x benefit. Overall, the results show that a thermally driven delay in the axial stage provides a greater NO x reduction than a mixing delay.

03 NATURAL GAS↗
DOE OSTI2022

Ultra-High Temperature Thermal Barrier Coating Development and Validation

The most effective method to improve industrial gas turbine power is to increase firing temperature. To maintain component durability at these higher temperatures, thermal barrier coatings (TBC’s) are playing an increasing role in protecting turbine hardware. TBC’s have been successfully used on Solar Turbines’ combustor liners and turbine airfoils, but there is a need for TBC’s that can operate at higher temperatures. Based on recent, favorable rig testing experience, Solar recognized that yttrium aluminum garnet (YAG) TBC’s made by the Solution Precursor Plasma Spray Process (SPPS) has great potential for higher turbine temperatures. This testing verified the thermal cycle durability of the SPPS YAG TBC’s, as well as demonstrated that the temperature drop through the SPPS YAG TBC was twice that measured across a companion APS YSZ TBC. The SPPS YAG TBC with the potential for a 200°C improvement in temperature capability represents a materials breakthrough. The SPPS process also produces a number of unique microstructural features that confer superior properties. SPPC TBC’s have ultra-fine splats that increase toughness and erosion resistance, and the process can be tailored to produce through-thickness cracks for strain-tolerance and control porosity for lower thermal conductivity and increase coating abradability. This proposal would include further development of SPPS YAG density-graded coatings, optimization of the application process, and validation of higher temperature capability and durability through rig and engine testing of coated combustion liners and turbine outer air seals. The technology would be advanced from a TRL 3 to a proposed TRL 6 by overcoming processing concerns on efficiency, application distance and optimization of a graded coating without impacting coating durability by demonstrating the coating performance on components in rig and development gas turbine engine testing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Bayesian optimization with active learning of design constraints using an entropy-based approach

Abstract The design of alloys for use in gas turbine engine blades is a complex task that involves balancing multiple objectives and constraints. Candidate alloys must be ductile at room temperature and retain their yield strength at high temperatures, as well as possess low density, high thermal conductivity, narrow solidification range, high solidus temperature, and a small linear thermal expansion coefficient. Traditional Integrated Computational Materials Engineering (ICME) methods are not sufficient for exploring combinatorially-vast alloy design spaces, optimizing for multiple objectives, nor ensuring that multiple constraints are met. In this work, we propose an approach for solving a constrained multi-objective materials design problem over a large composition space, specifically focusing on the Mo-Nb-Ti-V-W system as a representative Multi-Principal Element Alloy (MPEA) for potential use in next-generation gas turbine blades. Our approach is able to learn and adapt to unknown constraints in the design space, making decisions about the best course of action at each stage of the process. As a result, we identify 21 Pareto-optimal alloys that satisfy all constraints. Our proposed framework is significantly more efficient and faster than a brute force approach.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication, and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. Furthermore, it was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flowrates to achieve comparable levels of cooling performance.

Reynolds number↗
DOE OSTI2023

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. It was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flow rates to achieve comparable levels of cooling performance.

Fox, Andrew↗
DOE OSTI2022

Computation of conventional and alternative jet fuel sensitivity to lean blowout

Large Eddy Simulations (LES) are performed to compute the sensitivity of a conventional (A-2) and an alternate bio-jet (C-1) fuel to Lean Blowout (LBO). A realistic aviation gas turbine engine combustor configuration is considered. Reliable experimental LBO data and OH* chemiluminescence data for the conventional and alternate jet fuel in the combustor configuration have recently become available. The present work utilizes a highly automated, on-the-fly meshing strategy, along with adaptive mesh refinement, to demonstrate the feasibility of capturing the realistic combustion processes. A Lagrangian framework, with initial conditions specified using measurements of spray statistics, is used to model the fuel spray. Newly developed compact reaction mechanisms based on fuel surrogates are validated for the A-2 and the C-1 fuels. The compact reaction mechanisms are implemented using a detailed finite rate chemistry solver. Spray statistics computed by the present LES simulations compare well with available measurements at stable flame conditions near the lean blowout limit. The computed shape of the stable flame as represented by line integrated OH concentrations compares well with the experimental OH* chemiluminescence data. Lean blowout is reached by gradually decreasing the fuel flow rate in the computations, similar to that in the experiments. The results of the LES simulations effectively capture the fuel composition effects and estimate the sensitivity of the LBO limits to the fuel type. The computed trends in LBO limits agree within engineering accuracy with the experimental results for conventional and alternative aviation fuels. The methodology for predicting the fuel composition effects on the lean blowout limits in a fully resolved realistic, complex combustor is established for the first time.

Adaptive mesh refinement↗
DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗