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All sources NASA NTRS DOE OSTI

NASA NTRS1974

Hypersonic ramjet experiment project. Phase 1: Computer program description, ramjet and scramjet cycle performance

A computer program was developed to describe the performance of ramjet and scramjet cycles. The program performs one dimensional calculations of the equilibrium, real-gas internal flow properties of the engine. The program can be used for the following: (1) preliminary design calculation and (2) design analysis of internal flow properties corresponding to stipulated flow areas. Only the combustion of hydrogen in air is considered in this case.

Jackson, R. J.↗

NASA NTRS2003

Fuel Cell Propulsion Systems for an All-electric Personal Air Vehicle

There is a growing interest in the use of fuel cells as a power source for all-electric aircraft propulsion as a means to substantially reduce or eliminate environmentally harmful emissions. Among the technologies under consideration for these concepts are advanced proton exchange membrane and solid oxide fuel cells, alternative fuels and fuel processing, and fuel storage. This paper summarizes the results of a first-order feasibility study for an all-electric personal air vehicle utilizing a fuel cell-powered propulsion system. A representative aircraft with an internal combustion engine was chosen as a baseline to provide key parameters to the study, including engine power and subsystem mass, fuel storage volume and mass, and aircraft range. The engine, fuel tank, and associated ancillaries were then replaced with a fuel cell subsystem. Various configurations were considered including: a proton exchange membrane (PEM) fuel cell with liquid hydrogen storage; a direct methanol PEM fuel cell; and a direct internal reforming solid oxide fuel cell (SOFC)/turbine hybrid system using liquid methane fuel. Each configuration was compared to the baseline case on a mass and range basis.

Kohout, Lisa L.↗

NASA NTRS2003

Fuel Cell Propulsion Systems for an All-Electric Personal Air Vehicle

Kohout, Lisa L.↗

NASA NTRS2000

Experiment/Analytical Characterization of the RBCC Rocket-Ejector Mode

Experimental and complementary CFD results from the study of the rocket-ejector mode of a Rocket Based Combined Cycle (RBCC) engine are presented and discussed. The experiments involved systematic flowfield measurements in a two-dimensional, variable geometry rocket-ejector system. The rocket-ejector system utilizes a single two-dimensional, gaseous oxygen/gaseous hydrogen rocket as the ejector. To gain a thorough understanding of the rocket-ejector's internal fluid mechanic/combustion phenomena, experiments were conducted with both direct-connect and sea-level static configurations for a range of rocket operating conditions. Overall system performance was obtained through global measurements of wall static pressure profiles, heat flux profiles and engine thrust, whereas detailed mixing and combustion information was obtained through Raman spectroscopy measurements of major species (oxygen, hydrogen, nitrogen and water vapor). The experimental results for both the direct-connect and sea-level static configurations are compared with CFD predictions of the flowfield.

Ruf, J. H.↗

NASA NTRS1999

Focused Experimental and Analytical Studies of the RBCC Rocket-Ejector

The rocket-ejector mode of a Rocket Based Combined Cycle Engine (RBCC) was studied through a joint experimental/analytical approach. A two-dimensional variable geometry rocket-ejector system with enhanced optical access was designed and fabricated for experimentation. The rocket-ejector system utilizes a single two-dimensional gaseous oxygen/gaseous hydrogen rocket as the ejector. To gain a systematic understanding of the rocket ejector's internal fluid mechanic/combustion phenomena, experiments were conducted with both direct-connect and sea-level static configurations for a range of rocket operating conditions Overall system performance was obtained through Global measurements of wall static pressure profiles, heat flux profiles and engine thrust, whereas detailed mixing and combustion information was obtained through Raman spectroscopy measurements of major species (gaseous oxygen, hydrogen. nitrogen and water vapor). These experimental efforts were complemented by Computational Fluid Dynamic (CFD) flowfield analyses.

Lehman, M.↗

NASA NTRS1984

Advanced high temperature materials for the energy efficient automotive Stirling engine

The Stirling Engine is under investigated jointly by the Department of Energy and NASA Lewis as an alternative to the internal combustion engine for automotive applications. The Stirling Engine is an external combustion engine that offers the advantage of high fuel economy, low emissions, low noise, and low vibrations compared to current internal combustion automotive engines. The most critical component from a materials viewpoint is the heater head consisting of the cylinders, heating tubes, and regenerator housing. Materials requirements for the heater head include compatibility with hydrogen, resistance to hydrogen permeation, high temperature oxidation/corrosion resistance and high temperature creep-rupture and fatigue properties. A continuing supporting materials research and technology program has identified the wrought alloys CG-27 and 12RN72 and the cast alloys XF-818 and NASAUT 4G-A1 as candidate replacements for the cobalt containing alloys used in current prototype engines. Based on the materials research program in support of the automotive Stirling engine it is concluded that manufacture of the engine is feasible from low cost iron-base alloys rather than the cobalt alloys rather than the cobalt alloys used in prototype engines. This paper will present results of research that led to this conclusion.

Titran, R. H.↗

NASA NTRS1984

Stirling material technology

The Stirling engine is an external combustion engine that offers the advantage of high fuel economy, low emissions, low noise, and low vibrations compared to current internal combustion automotive engines. The most critical component from a materials viewpoint is the heater head consisting of the cylinders, heating tubes, and regenerator housing. Materials requirements for the heater head include compatibility with hydrogen, resistance to hydrogen permeation, high temperature oxidation/corrosion resistance, and high temperature creep-rupture and fatigue properties. A materials research and technology program identified the wrought alloys CG-27 and 12RN72 and the cast alloys XF-818, NASAUT 4G-A1, and NASACC-1 as candidate replacements for the cobalt containing alloys used in current prototype engines. It is concluded that manufacture of the engine is feasible from low cost iron-base alloys rather than the cobalt alloys used in prototype engines. Results of research that lead to this conclusion are presented.

Titran, R. H.↗

NASA NTRS2012

Requirements for a Hydrogen Powered All-Electric Manned Helicopter

The objective of this paper is to set propulsion system targets for an all-electric manned helicopter of ultra-light utility class to achieve performance comparable to combustion engines. The approach is to begin with a current two-seat helicopter (Robinson R 22 Beta II-like), design an all-electric power plant as replacement for its existing piston engine, and study performance of the new all-electric aircraft. The new power plant consists of high-pressure Proton Exchange Membrane fuel cells, hydrogen stored in 700 bar type-4 tanks, lithium-ion batteries, and an AC synchronous permanent magnet motor. The aircraft and the transmission are assumed to remain the same. The paper surveys the state of the art in each of these areas, synthesizes a power plant using best available technologies in each, examines the performance achievable by such a power plant, identifies key barriers, and sets future technology targets to achieve performance at par with current internal combustion engines.

Datta, Anubhav↗

DOE OSTI2024

Development of a micro-combined heat and power powered by an opposed-piston engine in building applications

Residential homes and light commercial buildings usually require substantial heat and electricity simultaneously. A combined heat and power system enables more efficient and environmentally friendly energy usage than that achieved when heat and electricity are produced in separate processes. However, due to financial and space constraints, residential and light commercial buildings often limit the use of traditional large-scale industrial equipment. Here we develop a micro–combined heat and power system powered by an opposed-piston engine to simultaneously generate electricity and provide heat to residential homes or light commercial buildings. The developed prototype attains the maximum AC electrical efficiency of 35.2%. The electrical efficiency breaks the typical upper boundary of 30% for micro–combined heat and power systems using small internal combustion engines (i.e., <10 kW). Moreover, the developed prototype enables maximum combined electrical and thermal efficiencies greater than 93%. The prototype is optimally designed for natural gas but can also run renewable biogas and hydrogen, supporting the transition from current conventional fossil fuels to zero carbon emissions in the future. The analysis of the unit’s decarbonization and cost-saving potential indicate that, except for specific locations, the developed prototype might excel in achieving decarbonization and cost savings primarily in US northern and middle climate zones.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1997

Thrust Enhancement in Hypervelocity Nozzles by Chemical Catalysis

In the hypersonic flight regime, the air-breathing supersonic combustion ramjet (scramjet) has been shown to be a viable propulsion system. The current designs of scramjet engines provide performance benefits only up to a Mach number of 14. Performance losses increase rapidly as the Mach number increases. To extend the applicability of scram'jets beyond Mach 14, research is being conducted in the area of inlet and wave drag reduction, skin-friction and heat-transfer reduction, nozzle loss minimization, low-loss mixing, and combustion enhancement. For high Mach number applications, hydrogen is the obvious fuel choice because of its high energy content per unit mass in comparison with conventional fuels. These flight conditions require engines to operate at supersonic internal velocities, high combustor temperatures, and low static pressures. The high static temperature condition enhances the production of radicals such as H and OH, and the low-pressure condition slows the reaction rates, particularly the recombination reactions. High-temperature and low-pressure constraints, in combination with a small residence time, result in a radical-rich exhaust gas mixture exiting the combustor. At high Mach number conditions (due to low residence time), H and OH do not have enough time to recombine ; thus, a significant amount of energy is lost as these high-energy free radical are exhausted. The objective of the present study is to conduct a flowfield analysis for a typical nozzle geometry for NASP-type vehicle to assess for thrust enhancement in hypervelocity nozzles by substituting small amount of phosphine for hydrogen.

Singh, D. J.↗

DOE OSTI2026

Admissible Powertrain Alternatives for Heavy-Duty Fleets: A Case Study on Resiliency and Efficiency

Heavy-duty vehicles dominate global freight movement and primarily rely on fossil-derived diesel fuel. However, fluctuations in crude oil prices and evolving emissions regulations have prompted interest in alternative powertrains to enhance fleet energy resiliency. This study paired real-world operational data from a large commercial fleet with high-fidelity vehicle models to evaluate the potential for replacing diesel internal combustion engine (ICE) trucks with alternative powertrain architectures. The baseline vehicle for this analysis is a diesel-powered ICE truck. Alternatives include ICE trucks fueled by bio- and renewable diesel, compressed natural gas (CNG) or hydrogen (H 2 ), as well as plug-in hybrid (PHEV), fuel cell electric (FCEV), and battery electric vehicles (BEV). While most alternative powertrains resulted in some payload capacity loss, the overall fleetwide impact was negligible due to underutilized payload capacity for the specific fleet considered in this study. For sleeper cab trucks, CNG-powered trucks achieved the highest replacement potential, covering 85% of the fleet. In contrast, H 2 and BEV architectures could replace fewer than 10% and 1% of trucks, respectively. Day cab trucks, with shorter daily routes, showed higher replacement potential: 98% for CNG, 78% for H 2 , and 34% for BEVs. However, achieving full fleet replacement would still require significant operational changes such as route reassignment and enroute refueling, along with considerable improvements to onboard energy storage capacity. Additionally, the higher total cost of ownership (TCO) for alternative powertrains remains a key challenge. This study also evaluated lifecycle impacts across various fuel sources, both fossil and bio-derived. Bio-derived synthetic diesel fuels emerged as a practical option for diesel displacement without disrupting operations. Conversely, H 2 and electrified powertrains provide limited lifecycle impacts under the current energy scenario. This analysis highlights the complexity of replacing diesel ICE trucks with admissible alternatives while balancing fleet resiliency, operational demands, and emissions goals. These results reflect a US-based fleet’s duty cycles, payloads, GVWR allowances, and an assumption of depot-only refueling/recharging. Applicability to other fleets and regions may differ based on differing routing practices or technical features such as battery swapping.

BEV↗

NASA NTRS1986

Alloy chemistry and microstructural control to meet the demands of the automotive Stirling engine

The automotive Stirling engine now under development by DOE/NASA as an alternative to the internal combustion engine, imposes severe materials requirements for the hot portion of the engine. Materials selected must be low cost and contain a minimum of strategic elements so that availability is not a problem. Heater head tubes contain high pressure hydrogen on the inside and are exposed to hot combustion gases on the outside surface. The cylinders and regenerator housings must be readily castable into complex shapes having varying wall thicknesses and be amenable to brazing and welding operations. Also, high strength, oxidation resistance, resistance to hydrogen permeation, cyclic operation, and long-life are required. A research program conducted by NASA Lewis focused on alloy chemistry and microstructural control to achieve the desired properties over the life of the engine. Results of alloy selection, characterization, evaluation, and actual engine testing of selected materials are presented.

Stephens, J. R.↗

NASA NTRS1988

Alloy chemistry and microstructural control to meet the demands of the automotive Stirling engine

Stephens, Joseph R.↗

DOE OSTI2024

Hydrogen Infrastructure Analysis for the Port Applications [Slides]

The International Maritime Organization has committed to 50% reduction in GHG emissions by 2050 worldwide as of 2023. This analysis includes performing an inventory and modeling efforts to understand the energy, equipment and cost requirements to support decarbonization of cargo handling and shore power at U.S. Ports, along with assessment of zero- and near- zero emission fuel supplies at or near U.S. ports focused upon Hydrogen technologies. Initial market assessment for ocean going vessels for harbor support and ocean-going vessels is explored. An energy analysis is performed on the port system using a holistic approach and considering the port as an entire ecosystem that functions as a transportation and energy node. Presently, a comprehensive view is lacking for future analysis efforts, this analysis seeks to address this gap in data by evaluating four representative port types and the potential for utilizing hydrogen for the maritime industry. Every port is different, but broadly they could be bracketed into reference cases with scaling factors for the relative size of the port operations. These reference ports are for future use, potentially as baselines for analysis and development of demonstration programs. An equipment inventory for each reference port type (container, bulk, breakbulk, and inland waterway) is presented. A comparative analysis of fuel cell electric and battery electric equipment is conducted based on the following criteria: technology readiness level, refueling/charging time, operational range, energy consumption, and fuel cost savings compared to baseline internal combustion engine equipment. The tradeoffs and synergies between two alternative powertrains is highlighted. Based on energy and infrastructure analysis, average and high equipment utilization profiles across different port types is identified and quantified baseline fuel and electricity demand for various decarbonization scenarios. Based on the portfolio of equipment converted to fuel cell electric, the estimates of initial capital investment are provided for hydrogen refueling stations across ports. An energy demand model is developed that predicts well the all-electric cargo handling equipment annual energy consumption for ports with annual tonnage under 2 million twenty-foot equivalent units (TEUs). The model is a good rubric to follow for further energy demand models that can create a scalable solution to understand the energy needs of cargo handling equipment, whether they are all-electric, hydrogen fuel cell, or powered by another fuel-type. Zero and near-zero emission fuel supply at ports is evaluated looking into the characteristics of hydrogen, ammonia, and methanol as an alternative fuel, as well as the bunkering status. The readiness of reference ports to produce ammonia or methanol and bunker the fuel is examined based on the framework developed by the Global Maritime Forum and Rocky Mountain Institute.

08 HYDROGEN↗

NASA NTRS2001

CFD Simulation of Liquid Rocket Engine Injectors

Detailed design issues associated with liquid rocket engine injectors and combustion chamber operation require CFD methodology which simulates highly three-dimensional, turbulent, vaporizing, and combusting flows. The primary utility of such simulations involves predicting multi-dimensional effects caused by specific injector configurations. SECA, Inc. and Engineering Sciences, Inc. have been developing appropriate computational methodology for NASA/MSFC for the past decade. CFD tools and computers have improved dramatically during this time period; however, the physical submodels used in these analyses must still remain relatively simple in order to produce useful results. Simulations of clustered coaxial and impinger injector elements for hydrogen and hydrocarbon fuels, which account for real fluid properties, is the immediate goal of this research. The spray combustion codes are based on the FDNS CFD code' and are structured to represent homogeneous and heterogeneous spray combustion. The homogeneous spray model treats the flow as a continuum of multi-phase, multicomponent fluids which move without thermal or velocity lags between the phases. Two heterogeneous models were developed: (1) a volume-of-fluid (VOF) model which represents the liquid core of coaxial or impinger jets and their atomization and vaporization, and (2) a Blob model which represents the injected streams as a cloud of droplets the size of the injector orifice which subsequently exhibit particle interaction, vaporization, and combustion. All of these spray models are computationally intensive, but this is unavoidable to accurately account for the complex physics and combustion which is to be predicted, Work is currently in progress to parallelize these codes to improve their computational efficiency. These spray combustion codes were used to simulate the three test cases which are the subject of the 2nd International Workshop on-Rocket Combustion Modeling. Such test cases are considered by these investigators to be very valuable for code validation because combustion kinetics, turbulence models and atomization models based on low pressure experiments of hydrogen air combustion do not adequately verify analytical or CFD submodels which are necessary to simulate rocket engine combustion. We wish to emphasize that the simulations which we prepared for this meeting are meant to test the accuracy of the approximations used in our general purpose spray combustion models, rather than represent a definitive analysis of each of the experiments which were conducted. Our goal is to accurately predict local temperatures and mixture ratios in rocket engines; hence predicting individual experiments is used only for code validation. To replace the conventional JANNAF standard axisymmetric finite-rate (TDK) computer code 2 for performance prediction with CFD cases, such codes must posses two features. Firstly, they must be as easy to use and of comparable run times for conventional performance predictions. Secondly, they must provide more detailed predictions of the flowfields near the injector face. Specifically, they must accurately predict the convective mixing of injected liquid propellants in terms of the injector element configurations.

Farmer, Richard↗

NASA NTRS1980

Preparing aircraft propulsion for a new era in energy and the environment

Improving fuel efficiency, new sources of jet fuel, and noise and emission control are subjects of NASA's aeronautics program. Projects aimed at attaining a 5% fuel savings for existing engines and a 13-22% savings for the next generation of turbofan engines using advanced components, and establishing a basis for turboprop-powered commercial air transports with 30-40% savings over conventional turbofan aircraft at comparable speeds and altitudes, are discussed. Fuel sources are considered in terms of reduced hydrogen and higher aromatic contents and resultant higher liner temperatures, and attention is given to lean burning, improved fuel atomization, higher freezing-point fuel, and deriving jet fuel from shale oil or coal. Noise sources including the fan, turbine, combustion process, and flow over internal struts, and attenuation using acoustic treatment, are discussed, while near-term reduction of polluting gaseous emissions at both low and high power, and far-term defining of the minimum gaseous-pollutant levels possible from turbine engines are also under study.

Stewart, W. L.↗

NASA NTRS2007

Fatigue Life of Haynes 188 Superalloy in Direct Connect Combustor Durability Rig

The Direct Connect Combustor Durability Rig (DCR) will provide NASA a flexible and efficient test bed to demonstrate the durability of actively cooled scramjet engine structure, static and dynamic sealing technologies, and thermal management techniques. The DCR shall be hydrogen fueled and cooled, and test hydrogen coolded structural panels at Mach 5 and 7. Actively cooled Haynes 188 superalloy DCR structural panels exposed to the combustion environment shall have electrodischarge machined (EDM) internal cooling holes with flowing liquid hydrogen. Hydrogen combustion could therefore produce severe thermal conditions that could challenge low cycle fatigue durability of this material. The objective of this study was to assess low cycle fatigue capability of Haynes 188 for DCR application. Tests were performed at 25 and 650 C, in hydrogen and helium environments, using specimens with low stress ground (LSG) and electro-discharge machined (EDM) surface finish. Initial fatigue tests in helium and hydrogen indicate the low cycle fatigue life capability of Haynes 188 in hydrogen appears quite satisfactory for the DCR application. Fatigue capability did not decrease with increasing test temperature. Fatigue capability also did not decrease with EDM surface finish. Failure evaluations indicate retention of ductility in all conditions. Additional tests are planned to reconfirm these positive trends.

Gabb, TIm↗

NASA NTRS1990

Technical accomplishments of the NASA Lewis Research Center, 1989

Topics addressed include: high-temperature composite materials; structural mechanics; fatigue life prediction for composite materials; internal computational fluid mechanics; instrumentation and controls; electronics; stirling engines; aeropropulsion and space propulsion programs, including a study of slush hydrogen; space power for use in the space station, in the Mars rover, and other applications; thermal management; plasma and radiation; cryogenic fluid management in space; microgravity physics; combustion in reduced gravity; test facilities and resources.

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