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At least 55 records · Page 3

Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. As a result, the methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.

Additive manufacturing↗

The Effect on Thrust Minus Base Drag of Exchanging Base Area for Nozzle Expansion in Supersonic Nozzles at Transonic Mach Numbers

A wind-tunnel investigation to determine the effect on thrust minus base drag of exchanging base area for nozzle overexpansion on a cylindrical afterbody with a single supersonic nozzle has been conducted a t Mach numbers from 0.9 t o 1.4. The throat-to-base diameter ratio has been varied from 0.320 to 0.550; the jet-to-base diameter ratio has been varied from 0.320 to 1, resulting in a jet Mach number variation of 1.0 to 3.897. The jet total-pressure ratio ranged from 2 to approximately 22. The results indicated that a proper balance between nozzle over-expansion and base area exists, which will produce the maximum afterbody net-thrust factor over a given operating range. For a given Mach number and throat-to-base diameter ratio, the optimum values of jet-to-base diameter ratio corresponding to the peak values of the net-thrust factor are, in general, larger than the values at the jet design pressure ratio and tend to increase with increasing j e t total-pressure ratio in a manner similar to the design values. Also, for given values of throat-to-base diameter ratio and jet total-pressure ratio, the optimum value of jet-to-base diameter ratio changed as the free-stream Mach number was varied from transonic to low supersonic speeds. The magnitude of the changes varied with jet total-pressure ratio and throat-to-base diameter ratio.

Slocumb, Travis H.↗

Extraction of Oxygen from the Martian Atmosphere

A mechanical process was designed for direct extraction of molecular oxygen from the martian atmosphere based on liquefaction of the majority component, CO2, followed by separation of the lower-boiling components. The atmospheric gases are compressed from about 0.007 bar to 13 bar and then cooled to liquefy most of the CO2. The uncondensed gases are further compressed to 30 bar or more, and then cooled again to recover water as ice and to remove much of the remaining CO2. The final gaseous products consisting mostly of nitrogen, oxygen, and carbon monoxide are liquefied and purified by cryogenic distillation. The liquefied CO2 is expanded back to the low-pressure atmosphere with the addition of heat to recover a majority of the compression energy and to produce the needed mechanical work. Energy for the process is needed primarily as heat to drive the CO2-based expansion power system. When properly configured, the extraction process can be a net producer of electricity. The conceptual design, termed 'MARRS' for Mars Atmosphere Resource Recovery System, was based on the NASA/JSC Mars Reference Mission (MRM) requirement for oxygen. This mission requires both liquid oxygen for propellant, and gaseous oxygen as a component of air for the mission crew. With single redundancy both for propellant and crew air, the oxygen requirement for the MRM is estimated at 5.8 kg/hr. The process thermal power needed is about 120 kW, which can be provided at 300-500 C. A lower-cost nuclear reactor made largely of stainless steel could serve as the heat source. The chief development needed for MARRS is an efficient atmospheric compression technology, all other steps being derived from conventional chemical engineering separations. The conceptual design describes an exceptionally low-mass compression system that can be made from ultra-lightweight and deployable structures. This system adapts to the rapidly changing martian environment to supply the atmospheric resource to MARRS at constant conditions.

England, C.↗

Accounting for linkages between wildfire-driven shifts in plant-microbial interactions and soil carbon dynamics in Arctic tundra

Increasing wildfire regimes in the rapidly changing Arctic tundra are altering the soil carbon budget through increased permafrost degradation, shrubs expansion, and shifts in microbial activities. Whether future arctic wildfires will result in net C losses or gains in the future will depend on complex biotic and abiotic interactions that regulate belowground C biogeochemical processes, including linkages among biotic communities. One important linkage is plant-microbe interactions. While these interactions are likely shaped or altered by wildfires, they remain little explored in the context of successional trajectories. Yet, incorporating plant-microbe interactions in frameworks for defining and understanding post-fire soil C trajectories is critical to predict belowground C responses to future tundra wildfires. Here, we provide examples of and discuss how fire-mediated changes in plant-soil-microbe (PSM) interactions can impact soil C dynamics in the Arctic tundra. We consider different impacts of wildfires on PSM interactions and their implications to soil C dynamics, as well as the nuances associated with particular wildfire regimes (severity and intensity) and successional timescales. We suggest that accounting for plant-microbial linkages in future wildfire-succession interactions frameworks can inform future experimental designs and reduce uncertainties in our ability to predict the net effect of Arctic wildfires on ecosystem C.

fungi, bacteria↗

Content and Representation of Information Needed to Support Time-Constrained Problem Solving

NASA’s current mission-operations paradigm originated with Project Mercury and endured with minimum evolution through the Apollo Program, Space Shuttle Program, and ISS missions. At its foundation is a near-complete real-time dependence on a ground team to manage the combined state of the mission, vehicle, and crew. Utilizing many engineers and operators with broad and deep expertise; large, distributed datasets including extensive telemetry; and expansive analytical and computing power, this ground team has served as the safety net for crewed spaceflight missions over the past 60 years. This approach must change to address challenges associated with missions beyond low Earth orbit (BLEO), including infrequent resupply, reduced ability to evacuate, and delayed communications that prohibit real-time operational support. We anticipate that a necessary part of this change will be increased independence for the crew, as roles and responsibilities traditionally performed by ground teams move on board the vehicle. While many risks are associated with Earth-independent operations, one particular concern is ensuring that the crew will have adequate onboard support to perform urgent problem solving when communication with the ground is delayed or intermittent. A key resource that enables the ground team to respond to anomalies quickly and effectively is the extraordinary expertise and experience it possesses. It is comprised of 80+ experts on at any given time, with a combined 600+ years of system-specific experience across 22 unique console disciplines. A small crew will face the unprecedented challenge of independently responding to anomalies that have historically been handled by a team 20 times their size. Another important resource upon which the ground heavily relies to support procedure execution and anomaly response is data. The amount of telemetry data that each flight controller monitors is extensive. In addition, as the ground team works to further assess impacts, trouble shoot, identify workarounds, and oversee procedure execution, it accesses and synthesizes engineering and procedure information, as well as system build, test, and configuration documentation. It is not feasible nor useful to put all these data onboard as crews become more Earth independent. Each member of a small Mars mission small crew will have multiple roles beyond monitoring telemetry and data gathering, and multiple roles within anomaly resolution processes, thereby limiting their capacity for copious amounts of information. Moreover, while access is necessary, it alone is insufficient. Information will need to be compiled, refined, and represented appropriately to support the crew’s reduced attention and expertise. This work seeks to understand the content and representation of information needed to support time-constrained problem solving and decision making by the crew without real-time ground support. To build this understanding, we first surveyed the literature, focusing on how expert problem solvers construct and manipulate their mental models. Next, we interviewed expert problem solvers in spaceflight and analogous domains and surveyed industry solutions for data presentation. Finally, we analyzed current spaceflight operations by investigating flight controller anomaly resolution processes during ISS training simulations and real operational events. These methods led to creating a problem-solving framework that details common themes and features of attending to, assessing, analyzing, and acting on problems in complex, time-constrained domains. Using this framework and the results of our analysis, we identified conceptual data representations needed for crew-led problem-solving. Preliminary onboard user interface concepts to meet identified needs will be presented.

anomaly response↗

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and Fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub element tests will be presented.

Shah, Sandeep↗

Shrub Expansion Simulations at Trail Valley Creek Tundra site using E3SM Land Model (ELM) Arctic-focused Version

The warming of the Arctic is causing substantial compositional, structural, and functional changes in tundra vegetation including shrub and densification in parts of the Arctic. Assessing the impact of these changes in vegetation composition on the Arctic’s carbon and energy budgets is important to constrain projected local and global surface-atmosphere exchanges. We conduct a sensitivity analysis of the projected surface energy fluxes, soil carbon pools, and carbon dioxide fluxes (net ecosystem exchange, gross primary production, and ecosystem respiration) between present day and 2100 to different shrub expansion rates and air temperature increases under future emission scenarios (intermediate – RCP4.5, and high – RCP8.5) using the Arctic-focused version of the Energy Exascale Earth System Model (E3SM) Land Model (ELM). We focus on Trail Valley Creek (TVC), a mineral upland tundra site located in the western Canadian Arctic, which is experiencing tall shrub densification and expansion. In this study, we run TVC under two different warming scenarios RCP4.5 and RCP 8.5 and simulate different shrubification rates projected until year 2100. In this repository, we include all the forcing, input, parameters, and output data corresponding to all the simulations performed. flmd.csv includes a detailed description of the datasets files.

54 ENVIRONMENTAL SCIENCES↗

Utilization of an Advanced Sensor network to determine fuel heating value and Real-Time net unit heat rate during transient operation

Coal-fired utility boilers are being increasingly used as variable electricity generation to resolve the imbalance in the energy market from the expansion of intermittent renewable energy. The frequent transient operation required to meet residual energy demand has created a challenge for coal-fired units to operate efficiently. This work utilizes an advanced sensor network (ASN) to calculate net unit heat rate (NUHR) of a coal-fired boiler in real time through combustion calculations and statistical correlations to provide the tools for optimizing dynamic operation. Real-time heating values that were necessary to determine fuel input energy to calculate accurate NUHR were found using both fundamental and data-driven methods. Real-time NUHR shows distinct shifts that reflect changes in process conditions that will improve the ability to optimize transient operation. Data-driven heating value correlations had 24% lower root mean square error (RMSE) than the fundamental combustion calculation approach when compared to daily retrospective proximate analysis. Furthermore, the data-driven method RMSE improved by 7% with the inclusion of ASN data. Future work is to validate by comparing unit performance with and without the inclusion of NUHR as a control parameter for the dynamic neural network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Duke Energy Carbon-Free Resource Integration Study

Duke Energy has partnered with the National Renewable Energy Laboratory (NREL) to evaluate pathways to achieving their carbon-free targets and to assess the operational impacts of the resulting system. This report details findings from Phase II of the Duke Low Carbon Resource Integration study, which consisted of three separate but interrelated analyses: (1) a resource assessment exploring the technical and economic potential and characteristics of wind and solar resources in the Carolinas; (2) capacity expansion modeling identifying the least-cost investment pathways for achieving 70% CO 2 emissions reductions in North Carolina by 2030 and a net-zero electricity system by 2050; and (3) detailed production cost modeling of power system operations at the higher shares of low- and zero-carbon emitting generation sources, informed by the capacity expansion modeling portion of the analysis. The analysis finds that Duke Energy can approach the 2030 and 2050 emissions target in North Carolina through investment in a combination of solar, wind, and storage along with maintaining its existing nuclear fleet. The average cost of CO 2 abatement in the Carolinas through 2021-2050 is on the order of $\$27-33$ per metric ton (range of $\$9-34$ per metric ton across key sensitivities).Duke Energy can expected increased interchange with neighbors to help balance higher levels of solar, although the ability to do this will depend on whether neighboring regions also move to integrate more carbon-free resources. As Duke Energy moves toward both the 2030 and 2050 targets, addressing energy needs during the winter peak period becomes particularly important, and the system relies on the availability of resources such as renewable or hydrogen combustion turbines, seasonal storage, or other similar technologies that are dispatchable but able to operate at low capacity factors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A kinetic study of fusion burn waves in compressed deuterium–tritium and proton–boron plasmas

We present particle-in-cell simulations with Monte Carlo collisions of fusion burn waves in compressed deuterium–tritium and proton–boron plasmas. We study the energy balance in the one-dimensional expansion of a hot-spot by simulating Coulomb collisions, fusion reactions, and bremsstrahlung emission with a Monte Carlo model and inverse bremsstrahlung absorption using a new PIC model. This allows us to self-consistently capture the alpha particle heating and radiative losses in the expanding hot-spot and surrounding cold fuel. After verifying our model in a code-to-code comparison with both kinetic and fluid codes for the case of a deuterium–tritium hot-spot, we simulate the expansion of a proton–boron hot-spot initialized at 200 keV and 1,000 g/cm 3 . Our model predicts that energy radiated by the hot-spot is recaptured by the surrounding high-density opaque fuel reducing the expansion work done by the propagating burn wave. As a result, we find the net fusion energy produced over the course of $20$~ps is twice the initial hot-spot energy independent of whether radiation physics is included.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Thermodynamics and wave processes in high Mach number propulsive ducts

Analysis of the flow in a propulsive duct indicates that, at high Mach numbers, the thermodynamic energy of the fluid is delivered directly into compression and expansion waves. The importance of the resulting wave phenomena is explored by considering the net thrust delivered by a two dimensional convergent-divergent duct with a simplified, planar heat addition zone. It is found that net thrust is reduced when operating at other than the design Mach number, an effect which is most severe for Mach numbers exceeding the design value. An idealized model is developed, involving a self-induced heat injection cycle, and it is seen that the waves produced by this cycle can be the dominant agency in producing thrust.

Stalker, R. J.↗

Vapor plumes: A neglected aspect of impact cratering

When a meteorite or comet strikes the surface of the planet or satellite at typical interplanetary velocities of 10-40 km/sec, the projectile and a quantity of the target body vaporize and expand out of the growing crater at high speed. The crater continues to grow after the vapor plume has formed and the series of ejecta deposits is laid down ballistically while the crater collapses into its final morphology. Although the vapor plume leaves little evidence of its existence in the crater structure of surface deposits, it may play a major role in a number of impact-related processes. The vapor plume expanding away from the site of an impact carries 25-50 percent of the total impact energy. Although the plume's total mass is only a few times the mass of the projectile, its high specific energy content means that it is the fastest and most highly shocked material in the cratering event. The mean velocity of expansion can easily exceed the escape velocity of the target plane, so that the net effect of a sufficiently high-speed impact is to erode material from the planet.

Melosh, H. J.↗

Insights into a Greener Stimuli-Responsive Fracturing Fluid for Geothermal Applications

StimuFracTM, is a non-toxic stimuli-responsive fracturing fluid consisting on a CO2-reactive polymer which has shown at the lab-scale to consistently fracture rock cores at significantly lower net pressures in a range of representative geothermal pressure/temperature conditions. In this work, we report on the two main mechanisms responsible for fracturing rock at lower net pressures with this novel fracturing fluid. The first mechanism is the additional work / overpressure generated by aqueous polymer solution during its CO2-triggered volume expansion. The second mechanism is associated to a reduction in pore invasion pressure as a result of the lower interfacial tension of StimuFrac. This reduction in pore invasion pressure results in a reduction in fracturing net pressure as previously reported. The results presented in this work illustrate the potential of StimuFrac as a greener and less-energy intensive fracturing fluid for geothermal and fossil energy production.

Fernandez, Carlos A.↗

Experimental Investigation of Low Cost, Low Thermal Conductivity Thermal Barrier Coating on HCCI Combustion, Efficiency, and Emissions

In-cylinder surface temperature is of heightened importance for Homogeneous Charge Compression Ignition (HCCI) combustion since the combustion mechanism is thermo-kinetically driven. Thermal Barrier Coatings (TBCs) selectively manipulate the in-cylinder surface temperature, providing an avenue for improving thermal and combustion efficiency. A surface temperature swing during combustion/expansion reduces heat transfer losses, leading to more complete combustion and reduced emissions. At the same time, achieving a highly dynamic response sidesteps preheating of charge during intake and eliminates the volumetric efficiency penalty. The magnitude and temporal profile of the dynamic surface temperature swing is affected by the TBC material properties, thickness, morphology, engine speed, and heat flux from the combustion process. This study follows prior work of authors with Yttria Stabilized Zirconia, which systematically engineered coatings for HCCI combustion. Herein, a modeling study was used to assess the impacts of various TBC material properties, e.g. density, thickness, and thermal conductivity on the temperature swing effect. Reducing conductivity emerged as a most promising avenue, rather than reducing both the density and effective conductivity by increasing porosity, the current work emphasizes a material with natively low conductivity. A novel TBC formulation was developed, leverages a class of materials that, to the author’s best knowledge, have not been used as a thermal barrier coating previously. Here, a systematic experimental investigation was carried out using single-cylinder research engine. Experimental engine studies utilizing the novel ‘glassy’ low-K coating exhibit advanced ignition phasing and reduced combustion duration relative to the baseline engine. Heat transfer measurements indicate a net reduction in heat flux over the entire cycle, although main effect is felt during expansion, and the reduced heat transfer losses manifest in higher gross indicated thermal efficiency by approximately 5-6% on a relative basis.

42 ENGINEERING↗

Detecting a Terrestrial Biosphere Sink for Carbon Dioxide: Interannual Ecosystem Modeling for the Mid-1980s

There is considerable uncertainty as to whether interannual variability in climate and terrestrial ecosystem production is sufficient to explain observed variation in atmospheric carbon content over the past 20-30 years. In this paper, we investigated the response of net CO2 exchange in terrestrial ecosystems to interannual climate variability (1983 to 1988) using global satellite observations as drivers for the NASA-CASA (Carnegie-Ames-Stanford Approach) simulation model. This computer model of net ecosystem production (NEP) is calibrated for interannual simulations driven by monthly satellite vegetation index data (NDVI) from the NOAA Advanced Very High Resolution Radiometer (AVHRR) at 1 degree spatial resolution. Major results from NASA-CASA simulations suggest that from 1985 to 1988, the northern middle-latitude zone (between 30 and 60 degrees N) was the principal region driving progressive annual increases in global net primary production (NPP; i.e., the terrestrial biosphere sink for carbon). The average annual increase in NPP over this predominantly northern forest zone was on the order of +0.4 Pg (10 (exp 15) g) C per year. This increase resulted mainly from notable expansion of the growing season for plant carbon fixation toward the zonal latitude extremes, a pattern uniquely demonstrated in our regional visualization results. A net biosphere source flux of CO2 in 1983-1984, coinciding with an El Nino event, was followed by a major recovery of global NEP in 1985 which lasted through 1987 as a net carbon sink of between 0.4 and 2.6 Avg C per year. Analysis of model controls on NPP and soil heterotrophic CO2 fluxes (Rh) suggests that regional warming in northern forests can enhance ecosystem production significantly. In seasonally dry tropical zones, periodic drought and temperature drying effects may carry over with at least a two-year lag time to adversely impact ecosystem production. These yearly patterns in our model-predicted NEP are consistent in magnitude with the estimated exchange of CO2 by the terrestrial biosphere with the atmosphere, as determined by previous isotopic (delta (sup 13 C) convolution analysis. Ecosystem simulation results can help further target locations where net carbon sink fluxes have occurred in the past or may be verified in subsequent field studies.

Potter, Christopher S.↗

Effects of Thermal Cycling on Thermal Expansion and Mechanical Properties of Sic Fiber-reinforced Reaction-bonded Si3n4 Composites

Thermal expansion curves for SiC fiber-reinforced reaction-bonded Si3N4 matrix composites (SiC/RBSN) and unreinforced RBSN were measured from 25 to 1400 C in nitrogen and in oxygen. The effects of fiber/matrix bonding and cycling on the thermal expansion curves and room-temperature tensile properties of unidirectional composites were determined. The measured thermal expansion curves were compared with those predicted from composite theory. Predicted thermal expansion curves parallel to the fiber direction for both bonding cases were similar to that of the weakly bonded composites, but those normal to the fiber direction for both bonding cases resulted in no net dimensional changes at room temperature, and no loss in tensile properties from the as-fabricated condition. In contrast, thermal cycling in oxygen for both composites caused volume expansion primarily due to internal oxidation of RBSN. Cyclic oxidation affected the mechanical properties of the weakly bonded SiC/RBSN composites the most, resulting in loss of strain capability beyond matrix fracture and catastrophic, brittle fracture. Increased bonding between the SiC fiber and RBSN matrix due to oxidation of the carbon-rich fiber surface coating and an altered residual stress pattern in the composite due to internal oxidation of the matrix are the main reasons for the poor mechanical performance of these composites.

Bhatt, R. T.↗