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NASA NTRS2008

Damage Propagation Modeling for Aircraft Engine Prognostics

This paper describes how damage propagation can be modeled within the modules of aircraft gas turbine engines. To that end, response surfaces of all sensors are generated via a thermo-dynamical simulation model for the engine as a function of variations of flow and efficiency of the modules of interest. An exponential rate of change for flow and efficiency loss was imposed for each data set, starting at a randomly chosen initial deterioration set point. The rate of change of the flow and efficiency denotes an otherwise unspecified fault with increasingly worsening effect. The rates of change of the faults were constrained to an upper threshold but were otherwise chosen randomly. Damage propagation was allowed to continue until a failure criterion was reached. A health index was defined as the minimum of several superimposed operational margins at any given time instant and the failure criterion is reached when health index reaches zero. Output of the model was the time series (cycles) of sensed measurements typically available from aircraft gas turbine engines. The data generated were used as challenge data for the Prognostics and Health Management (PHM) data competition at PHM 08.

Saxena, Abhinav↗

NASA NTRSDate not supplied

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric surface imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method models. Data collection methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps on how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the pre-processing methods and results from Py_TIGIRS are provided and compared for Composite Test Article (CTA) 8.2B. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future development of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Sandwich structures↗

NASA NTRS1985

Oxidizing seal for a turbine tip gas path

The sealing of the gas path in a gas turbine engine at the blade tips is improved by maintaining a minimum clearance between the rotor blade tips and the gas path seal. This is accomplished by taking advantage of an increase in volume during controlled oxidation of certain intermetallic compounds which have high melting points. The increase in volume closes the clearance subsequent to a rub between the blades and the seal. Thus, these compounds re-form the tip seal surface to assure continued engine efficiency.

Cawley, J. D.↗

NASA NTRS1989

Heat transfer to throat tubes in a square-chambered rocket engine at the NASA Lewis Research Center

A gaseous H2/O2 rocket engine was constructed at the NASA-Lewis to provide a high heat flux source representative of the heat flux to the blades in the high pressure fuel turbopump (HPFTP) during startup of the space shuttle main engines. The high heat flux source was required to evaluate the durability of thermal barrier coatings being investigated for use on these blades. The heat transfer, and specifically, the heat flux to tubes located at the throat of the test rocket engine was evaluated and compared to the heat flux to the blades in the HPFTP during engine startup. Gas temperatures, pressures and heat transfer coefficients in the test rocket engine were measured. Near surface metal temperatures below thin thermal barrier coatings were also measured at various angular orientations around the throat tube to indicate the angular dependence of the heat transfer coefficients. A finite difference model for a throat tube was developed and a thermal analysis was performed using the measured gas temperatures and the derived heat transfer coefficients to predict metal temperatures in the tube. Near surface metal temperatures of an uncoated throat tube were measured at the stagnation point and showed good agreement with temperatures predicted by the thermal model. The maximum heat flux to the throat tube was calculated and compared to that predicted for the leading edge of an HPFTP blade. It is shown that the heat flux to an uncooled throat tube is slightly greater than the heat flux to an HPFTP blade during engine startup.

Nesbitt, James A.↗

NASA NTRS2014

Implementation of an Ultra-Bright Thermographic Phosphor for Gas Turbine Engine Temperature Measurements

The overall goal of the Aeronautics Research Mission Directorate (ARMD) Seedling Phase II effort was to build on the promising temperature-sensing characteristics of the ultrabright thermographic phosphor Cr-doped gadolinium aluminum perovskite (Cr:GAP) demonstrated in Phase I by transitioning towards an engine environment implementation. The strategy adopted was to take advantage of the unprecedented retention of ultra-bright luminescence from Cr:GAP at temperatures over 1000 C to enable fast 2D temperature mapping of actual component surfaces as well as to utilize inexpensive low-power laser-diode excitation suitable for on-wing diagnostics. A special emphasis was placed on establishing Cr:GAP luminescence-based surface temperature mapping as a new tool for evaluating engine component surface cooling effectiveness.

temperature↗

DOE OSTI2025

Prototype Hanford Barrier Performance Monitoring Report: Fiscal Year 2024

This report provides an annual update on performance monitoring of the Prototype Hanford Barrier (PHB) at the Hanford Site. The PHB is part of a long-term study that serves as the scientific basis for many of the evapotranspiration-capillary barrier designs currently used globally and for future engineered barrier designs planned for remedial actions over waste and demolition sites at the Hanford Site. The PHB allows us to identify potential future issues and develop better monitoring techniques before these engineered barriers are constructed. Surface barriers like the PHB are essential for preventing water infiltration and curbing the spread of contaminants to groundwater. Effective monitoring of soil moisture levels above and below these barriers is crucial given that performance metrics could span up to 1,000 years. From July 2023 to June 2024, the water flux (as measured by tipping buckets) through the 2-m-thick silt loam layer of the PHB – a fine silty material that stores water under high capillary tension – remained well below the 0.5-mm-per-year performance threshold, demonstrating its effectiveness in preventing water penetration. In 2024, degraded tipping bucket gauges were replaced to ensure the accuracy of future data. Additionally, neutron probes revealed that the wetting front from the rainy season only penetrated to a maximum depth of 1.2 m into the silt loam. This further demonstrated the barrier's efficiency, as the wetting front did not fully penetrate the 2-m-thick capillary barrier. The western gravel slope of the PHB, composed of Hanford Site pit gravel of varying sizes, demonstrated low flux rates. In contrast, the eastern riprap slope exhibited higher flux rates. Zhang (2017) found that the riprap side slope of the PHB had the highest drainage rates in January and the lowest in late summer or early fall, indicating significant summer evaporation. Drainage rates increased significantly under enhanced precipitation conditions, far exceeding the design criterion, which could lead to water infiltration into the waste zone. The study introduced the “edge effect,” where elevated drainage rates from the riprap may migrate laterally beneath the barrier, compromising its ability to isolate waste, and recommended expanding the barrier and conducting further research to mitigate this issue. This report provides a review on surface barrier edge effects and their potential impact to subsurface contaminant migration.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1990

Pool boiler heat transport system for a 25 kWe advanced Stirling conversion system

Experiments to determine alkali metal/enhanced surface combinations that have stable boiling at the temperatures and heat fluxes that occur in the Stirling engine are reported. Two enhanced surfaces and two alkali metal working fluids were evaluated. The enhanced surfaces were an EDM hole covered surface and a sintered-powder-metal porous layer surface. The working fluids tested were potassium and eutectic sodium-potasium alloy (NaK), both with and without undissolved noncondensible gas. Noncondensible gas (He and Xe) was added to the system to provide gas in the nucleation sites, preventing quenching of the sites. The experiments demonstrated the potential of an alkali metal pool boiler heat transport system for use in a solar-powered Stirling engine. The most favorable fluid/surface combination tested was NaK boiling on a -100 +140 mesh 304L stainless steel sintered porous layer with no undissolved noncondensible gas. This combination provided stable, high-performance boiling at the operating temperature of 700 C. Heat fluxes into the system ranged from 10 to 50 W/sq cm. The transition from free convection to nucleate boiling occurred at temperatures near 540 C. Based on these experiments, a pool boiler was designed for a full-scale 25-kWe Stirling system.

Anderson, W. G.↗

DOE OSTI2025

Enhancement to the conductivity of surface transfer-doped (111) diamond through thermochemical surface etching

The use of a transition metal catalyzed thermochemical etching method for improving the carrier transport properties of the near-surface two-dimensional (2D) hole gas in surface transfer-doped hydrogen-terminated (111) diamond is demonstrated. Using Ni 0.8 Cr 0.2 films deposited and annealed to a temperature of 900 °C, with up to three etch cycles, preferential (111) surface etching produces large terraces exceeding 10 μm in size with a surface microroughness, σ 2 RMS λ, that is two orders of magnitude lower than for the pre-etched (111) surface. Magnetotransport measurements on hydrogen-terminated Hall bars engineered on the pre- and post-etched surfaces and rendered conductive by the adsorbed water layer formed on exposure to ambient conditions demonstrate that this etching causes an improvement in the hole mobility by an order of magnitude, resulting in a measured sheet resistivity of 1.04 kΩ/sq at a temperature of 4.2 K without gating.

42 ENGINEERING↗

NASA NTRS2010

High-Temperature Surface-Acoustic-Wave Transducer

Aircraft-engine rotating equipment usually operates at high temperature and stress. Non-invasive inspection of microcracks in those components poses a challenge for the non-destructive evaluation community. A low-profile ultrasonic guided wave sensor can detect cracks in situ. The key feature of the sensor is that it should withstand high temperatures and excite strong surface wave energy to inspect surface/subsurface cracks. As far as the innovators know at the time of this reporting, there is no existing sensor that is mounted to the rotor disks for crack inspection; the most often used technology includes fluorescent penetrant inspection or eddy-current probes for disassembled part inspection. An efficient, high-temperature, low-profile surface acoustic wave transducer design has been identified and tested for nondestructive evaluation of structures or materials. The development is a Sol-Gel bismuth titanate-based surface-acoustic-wave (SAW) sensor that can generate efficient surface acoustic waves for crack inspection. The produced sensor is very thin (submillimeter), and can generate surface waves up to 540 C. Finite element analysis of the SAW transducer design was performed to predict the sensor behavior, and experimental studies confirmed the results. One major uniqueness of the Sol-Gel bismuth titanate SAW sensor is that it is easy to implement to structures of various shapes. With a spray coating process, the sensor can be applied to surfaces of large curvatures. Second, the sensor is very thin (as a coating) and has very minimal effect on airflow or rotating equipment imbalance. Third, it can withstand temperatures up to 530 C, which is very useful for engine applications where high temperature is an issue.

Zhao, Xiaoliang↗

NASA NTRS2007

Technical Findings, Lessons Learned, and Recommendations Resulting from the Helios Prototype Vehicle Mishap

The Helios Prototype was originally planned to be two separate vehicles, but because of resource limitations only one vehicle was developed to demonstrate two missions. The vehicle consisted of two configurations, one for each mission. One configuration, designated HP01, was designed to operate at extremely high altitudes using batteries and high-efficiency solar cells spread across the upper surface of its 247-foot wingspan. On August 13, 2001, the HP01 configuration reached an altitude of 96,863 feet, a world record for sustained horizontal flight by a winged aircraft. The other configuration, designated HP03, was designed for long-duration flight. The plan was to use the solar cells to power the vehicle's electric motors and subsystems during the day and to use a modified commercial hydrogen-air fuel cell system for use during the night. The aircraft design used wing dihedral, engine power, elevator control surfaces, and a stability augmentation and control system to provide aerodynamic stability and control. At about 30 minutes into the second flight of HP03, the aircraft encountered a disturbance in the way of turbulence and morphed into an unexpected, persistent, high dihedral configuration. As a result of the persistent high dihedral, the aircraft became unstable in a very divergent pitch mode in which the airspeed excursions from the nominal flight speed about doubled every cycle of the oscillation. The aircraft s design airspeed was subsequently exceeded and the resulting high dynamic pressures caused the wing leading edge secondary structure on the outer wing panels to fail and the solar cells and skin on the upper surface of the wing to rip away. As a result, the vehicle lost its ability to maintain lift, fell into the Pacific Ocean within the confines of the U.S. Navy's Pacific Missile Range Facility, and was destroyed. This paper describes the mishap and its causes, and presents the technical recommendations and lessons learned for improving the design, analysis, and testing methods and techniques required for this class of vehicle.

Noll, Thomas E.↗

NASA NTRS2015

Evaluating the Utility of Satellite Soil Moisture Retrievals over Irrigated Areas and the Ability of Land Data Assimilation Methods to Correct for Unmodeled Processes

Earth's land surface is characterized by tremendous natural heterogeneity and human-engineered modifications, both of which are challenging to represent in land surface models. Satellite remote sensing is often the most practical and effective method to observe the land surface over large geographical areas. Agricultural irrigation is an important human-induced modification to natural land surface processes, as it is pervasive across the world and because of its significant influence on the regional and global water budgets. In this article, irrigation is used as an example of a human-engineered, often unmodeled land surface process, and the utility of satellite soil moisture retrievals over irrigated areas in the continental US is examined. Such retrievals are based on passive or active microwave observations from the Advanced Microwave Scanning Radiometer for the Earth Observing System (AMSR-E), the Advanced Microwave Scanning Radiometer 2 (AMSR2), the Soil Moisture Ocean Salinity (SMOS) mission, WindSat and the Advanced Scatterometer (ASCAT). The analysis suggests that the skill of these retrievals for representing irrigation effects is mixed, with ASCAT-based products somewhat more skillful than SMOS and AMSR2 products. The article then examines the suitability of typical bias correction strategies in current land data assimilation systems when unmodeled processes dominate the bias between the model and the observations. Using a suite of synthetic experiments that includes bias correction strategies such as quantile mapping and trained forward modeling, it is demonstrated that the bias correction practices lead to the exclusion of the signals from unmodeled processes, if these processes are the major source of the biases. It is further shown that new methods are needed to preserve the observational information about unmodeled processes during data assimilation.

land data↗

DOE OSTI2024

Inverse design of pore wall chemistry and topology through active learning of surface group interactions

Design of next-generation membranes requires a nanoscopic understanding of the effect of biologically inspired heterogeneous surface chemistries and topologies (roughness) on local water and solute behavior. In particular, the rejection of small, neutral solutes, such as boric acid, poses a heretofore unsolved challenge. In prior work, a computational inverse design technique using an evolutionary optimization successfully uncovered new surface design strategies for optimized transport of water over solutes in smooth, model pores consisting of two surface chemistries. However, extending such an approach to more complex (and realistic) scenarios involving many surface chemistries as well as surface roughness is challenging due to the expanded design space. In this work, we develop a new approach that uses active learning to optimize in a reduced feature space of surface group interactions, finding parameters that lead to their assembly into ordered, optimal patterns. This approach rapidly identifies novel surface functionalizations that maximize the difference in water and boric acid transport through the nanopore. Moreover, we find that the roughness of the nanopore wall, independent of its chemistry, can be leveraged to enhance transport selectivity: oscillations in the pore wall diameter optimally inhibit boric acid transport by creating energetic wells from which the solute must escape to transport down the pore. Furthermore, this proof-of-concept demonstrates the potential for active learning strategies, in concert with molecular simulations, to rapidly navigate complex design spaces of aqueous interfaces and is promising as a tool for engineering water-mediated surface interactions for a broad range of applications.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Remote Sensing of Surficial Process Responses to Extreme Meteorological Events

Changes in the frequency and magnitude of extreme meteorological events are associated with changing environmental means. Such events are important in human affairs, and can also be investigated by orbital remote sensing. During the course of this project, we applied ERS-1, ERS-2, Radarsat, and an airborne sensor (AIRSAR-TOPSAR) to measure flood extents, flood water surface profiles, and flood depths. We established a World Wide Web site (the Dartmouth Flood Observatory) for publishing remote sensing-based maps of contemporary floods worldwide; this is also an online "active archive" that presently constitutes the only global compilation of extreme flood events. We prepared an article for EOS concerning SAR imaging of the Mississippi Valley flood; an article for the International Journal of Remote Sensing on measurement of a river flood wave using ERS-2, began work on an article (since completed and published) on the Flood Observatory for a Geoscience Information Society Proceedings volume, and presented lectures at several Geol. Soc. of America Natl. Meetings, an Assoc. of Amer. Geographers Natl. Meeting, and a Binghamton Geomorphology Symposium (all on SAR remote sensing of the Mississippi Valley flood). We expanded in-house modeling capabilities by installing the latest version of the Army Corps of Engineers RMA two-dimensional hydraulics software and BYU Engineering Graphics Lab's Surface Water Modeling System (finite elements based pre- and post-processors for RMA work) and also added watershed modeling software. We are presently comparing the results of the 2-d flow models with SAR image data. The grant also supported several important upgrades of pc-based remote sensing infrastructure at Dartmouth. During work on this grant, we collaborated with several workers at the U.S. Army Corps of Engineers, Remote Sensing/GIS laboratory (for flood inundation mapping and modeling; particularly of the Illinois River using the AIRSAR/TOPSAR/ERS-2 combined data), with Dr. Karen Prestegaard at the University of Maryland (geomorphological responses to the extreme 1993 flood along the Raccoon drainage in central Iowa), and with Mr Tim Scrom of the Albany National Weather Service River Forecast Center (initial planning for the use of Radarsat and ERS-2 for flood warning). The work thus initiated with this proposal is continuing.

Brakenridge, G. Robert↗

DOE OSTI2025

A Geometric Volume of Fluid-Based Multiphase Flow Solver Extension to the Reacting Flow Solver, PeleLM

A new algorithm is presented to simulate multiphase flows with surface tension in a pathway for spray combustion simulation. The algorithm combines capabilities from two open-source packages, including the interface reconstruction library (IRL), a library of computational geometry routines to enable the volume of fluid (VOF) method, and PeleLM, a solver for the reacting Navier-Stokes equations. Additionally, surface tension is implemented using the continuum surface force (CSF) model with an improved height function technique in the volume fraction field. Spurious errors in volume fraction arising from our combined strategy are corrected through a topology-based method that improves both numerical stability and accuracy. Multiple validation simulations are conducted, including (i) translations and rotations of Zalesak's disk, (ii) a stationary circular droplet with surface tension, (iii) an oscillating elliptical droplet, and (iv) three-dimensional deformation of a spherical droplet. Results indicate that the combined scheme retains the favorable properties of each of the component algorithms.

42 ENGINEERING↗

DOE OSTI2020

An energy model of droplet impingement on an inclined wall under isothermal and non-isothermal environments

The observation of spray-wall interaction is of great importance to understand the dynamics that occur during fuel impingement onto the chamber wall or piston surfaces in internal combustion engines. It is found that the maximum spreading length of an impinged droplet can provide a quantitative estimation of heat transfer and energy transformation for spray-wall interaction. Furthermore, it influences the air-fuel mixing and hydrocarbon and particle emissions at combusting conditions. In this paper, an analytical model of different droplet-wall impingement conditions is developed in terms of βm (dimensionless maximum spreading length, the ratio of maximum spreading length to initial droplet diameter) to understand the detailed impinging dynamic process. These conditions are grouped as: a single diesel droplet impinging on the wall with different inclined angles (α); cold wall - heated droplet and heated wall - cold droplet impingement when inclined angle of the wall is 0°, respectively. The analytical model is built up based on the energy conservation that considers kinetic energy, gravitation energy, and surface energy before impingement, as well as viscous dissipation, gravitation energy, adhesion energy, deformation energy, and heat energy after impingement. The experimental work of diesel droplet impinging on an inclined wall is performed at a certain range of the Weber number (We of 33 to 420) with various inclined angles (α of 0° to 45°), while for inclined angle is 0°, droplet and wall temperature are varied from 25°C to 150°C to study the effects of the inclined angle and temperature on the temporal evolution of the post-impingement characteristics (i.e. droplet spreading length, dynamic contact angle). The analytical model is validated and evaluated at the aforementioned experimental operating points. The validated model can be employed to predict maximum spreading length of the droplet impinged on the wall. It is further utilized to determine the transition from capillary regime to kinetic regime, then to viscous regime at different inclined angle of the wall.

42 ENGINEERING↗

DOE OSTI2025

FY25 Cellular Silicone Foam Friction Testing Summary Report

This effort was a collaboration between LANL groups MPA-CINT, E-13, and V-14 to characterize various properties of foam materials for programmatic work. Specifically, MPA-CINT staff members’ contribution to this effort was to perform friction testing of cellular silicone foams of two different porosities with respect to two engineering materials with predefined surface roughnesses. The selected foams (henceforth serving as the sled material interface exposed to motion) had porosities of 67% and 70% with respect to fabricated values. The other materials used in the friction testing measurement couple (static track material) were 304 Stainless Steel (304 SS) and Very High-Temperature Glass-Mica Ceramic, known as Macor®.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Micro-trench measurements of the net deposition of carbon impurity ions in the DIII-D divertor and the resulting suppression of surface erosion

In this work, we report carbon impurity ion incident angles and deposition rates, along with silicon erosion rates, from measurements of micro-engineered trenches on a silicon surface exposed to L-mode deuterium plasmas at the DIII-D divertor. Post exposure ex-situ analysis determined elemental maps and concentrations, carbon deposition thicknesses, and erosion of silicon surfaces. Carbon deposition profiles on the trench floor showed carbon ion shadowing that was consistent with ERO calculations of average carbon ion angle distributions (IADs) for both polar and azimuthal angles. Measured silicon net erosion rates negatively correlated with the deposited carbon concentration at different locations. Differential erosion of surfaces on two different ion-downstream trench slope structures suggested that carbon deposition rate is affected by the carbon ion incident angle and significantly suppressed the surface erosion. The results suggest the C impurity ion incident angles, determined by the IADs and surface morphology, strongly affect erosion rates as well as the main ion (D, T, He) incident angles.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

In-situ polarization modulation IRRAS investigation of ammonia electrooxidation on Pt-Ir and Pt-Ru nanoparticles prepared on engineered catalyst supports

The catalytic activity and surface reactivity of monometallic Pt and bimetallic Pt-Ir and Pt-Ru nanoparticles, supported on two distinct Engineered Catalyst Supports (ECSs), were investigated for the Ammonia Electrooxidation Reaction (AmER) in alkaline media. XRD measurements confirmed alloy formation between Pt-Ir and Pt-Ru nanoparticles, as indicated by the shift of the (111) reflection to higher 2θ values. Cyclic voltammetry, linear sweep voltammetry, and chronoamperometry experiments were conducted to assess the catalytic activity of the Pt, Pt-Ir, and Pt-Ru electrocatalysts. All bimetallic catalysts exhibited lower onset potentials compared to Pt. The differing Tafel slopes between Pt (74 mV dec⁻¹), Pt-Ir (152 mV dec⁻¹), and Pt-Ru (118–197 mV dec⁻¹) suggest that alloying Pt with Ir or Ru alters the reaction mechanisms. Furthermore, the bimetallic Pt-Ir and Pt-Ru catalysts demonstrated greater tolerance for concentrated ammonia solutions relative to Pt. In-situ Polarization Modulation Infrared Reflection Absorption Spectroscopy (PM-IRRAS) provided insights into the formation of N-H species, azide anions (N₃⁻), and N-O compounds. For the Pt-Ru catalyst, an additional peak around ~3600 cm⁻¹ was observed, corresponding to OH⁻ species. The PM-IRRAS results align with the Gerischer–Mauerer mechanism, indicating that partially dehydrogenated ammonia adsorbates act as active intermediates in the oxidation of ammonia over Pt-Ir and Pt-Ru catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗