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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

Aerodynamic performance of a fully film cooled core turbine vane tested with cold air in a two-dimensional cascade

The aerodynamic performance of a fully film cooled core turbine vane was investigated experimentally in a two-dimensional cascade of 10 vanes. Three of the 10 vanes were cooled; the others were solid (uncooled) vanes. Cold air was used for both the primary and coolant flows. The cascade test covered a range of pressure ratios corresponding to ideal exit critical velocity ratios of 0.6 to 0.95 and a range of coolant flow rates to 7.5 percent of the primary flow. The coolant flow was varied by changing the coolant supply pressure. The principal measurements were cross-channel surveys of exit total pressure, static pressure, and flow angle. The results presented include exit survey data and overall performance in terms of loss, flow angle, and weight flow for the range of exit velocity ratios and coolant flows investigated. The performance of the cooled vane is compared with the performance of an uncooled vane of the same profile and also with the performance obtained with a single cooled vane in the 10-vane cascade.

Stabe, R. G.↗
NASA NTRSDate not supplied

Preliminary Findings of the Experimental Development Unit Cold Flow Test for a Generation Zero Nuclear Propulsion Engine

Nuclear thermal propulsion (NTP) technology will greatly benefit human travel to Mars by significantly shortening transit times, improving crew safety, and providing more mission flexibility than traditional chemical rockets. As part of DRACO follow-on work to develop, build, and fly a generation zero NTP engine, a full scale flight-like experimental design unit (EDU) reactor was constructed to collect sufficient on-ground performance data to characterize flow induced vibrations (FIV) of critical reactor structures/components, inform development of the engine and reactor control algorithm, and collect pressure drop and flow distribution data across the reactor. The fluid conditions for the test program were designed to achieve system responses equivalent to that of an operational engine through all phases of engine operation including reactor startup, mainstage operation, reactor shutdown, and reactor cooldown. Over 100 tests were executed, flowing either GN2 or GHe through the EDU at varying flow rates and pressures. This experiment provided early validation of flow behavior and vibration risks before nuclear testing, boosted critical subsystem TRLs, informed design iterations, and reduced future test costs. The steady-state flow parameters for the experiment were modeled in Ansys Thermal Desktop, allowing rapid tuning and experiment-informed updates to a flight-like test matrix. The EDU dynamic environment was characterized with accelerometers, strain gauges, and high-frequency pressure transducers all sampled at 20 kHz. While many narrow-band oscillations were identified, no significant FIV occurred; the reactor structural responses tend to be enveloped by typical launch vehicle ascent vibration environments (defined up to 2 kHz), although significant energy is also present at higher frequencies.

Flow Induced Vibration↗
DOE OSTI2023

HB650 Cryomodule Design: From Prototype to Production

In early 2023 the assembly of the prototype HB650 cryomodule (pHB650 CM) was completed and cold tests started to evaluate its performance. The lessons learned from the design, assembly and preliminary cold tests of this cryomodule, and from the design of the SSR2 pre-production cryomodule played a fundamental role during the design optimization process of the production HB650 cryomodule (HB650 CM). Several workshops have been organized to share experiences and solve problems. This paper presents the main design changes from pHB650 to the HB650 production cryomodules and their impact on the heat loads.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Development and Performance of RFD Crab Cavity Prototypes for HL-LHC AUP

The US will be contributing to the HL-LHC upgrade at CERN with the fabrication and qualification of RFD crabbing cavities in the framework of the HL-LHC Accelerator Upgrade Project (AUP) managed by Fermilab. AUP received Critical Decision 3 (CD-3) approval by DOE in December 2020 launching the project into the production phase. The electro-magnetic design of the cavity was inherited from the LHC Accelerator Research Program (LARP) but needed to be revised to meet new project requirements and to prevent issues encountered during beam tests performed at CERN in the R&D phase. Two prototype cavities were manufactured in industry and cold tested. Challenges specific to the RFD cavity were the stringent interface tolerances, the pole symmetry, and the higher-order-mode impedance spectrum. Chemical processing and heat treatments were performed initially at FNAL/ANL and are now being transferred to industry for the production phase. HOM dampers are manufactured and validated by JLAB. A summary of cold test results with and without HOM dampers is presented.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Development and Performance of RFD Crab Cavity Prototypes for HL-LHC AUP

The US will be contributing to the HL-LHC upgrade at CERN with the fabrication and qualification of RFD crabbing cavities in the framework of the HL-LHC Accelerator Upgrade Project (AUP) managed by Fermilab. AUP received Critical Decision 3 (CD-3) approval by DOE in December 2020 launching the project into the production phase. The electro-magnetic design of the cavity was inherited from the LHC Accelerator Research Program (LARP) but needed to be revised to meet new project requirements and to prevent issues encountered during beam tests performed at CERN in the R&D phase. Two prototype cavities were manufactured in industry and cold tested. Challenges specific to the RFD cavity were the stringent interface tolerances, the pole symmetry, and the higher-order-mode impedance spectrum. Chemical pro-cessing and heat treatments were performed initially at FNAL/ANL and are now being transferred to industry for the production phase. HOM dampers are manufactured and validated by JLAB. A summary of cold test results with and without HOM dampers is presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1993

Single element injector cold flow testing for STME swirl coaxial injector element design

An oxidizer-swirled coaxial element injector is being investigated for application in the Space Transportation Main Engine (STME). Single element cold flow experiments were conducted to provide characterization of the STME injector element for future analysis, design, and optimization. All tests were conducted to quiescent, ambient backpressure conditions. Spray angle, circumferential spray uniformity, dropsize, and dropsize distribution were measured in water-only and water/nitrogen flows. Rupe mixing efficiency was measured using water/sucrose solution flows with a large grid patternator for simple comparative evaluation of mixing. Factorial designs of experiment were used for statistical evaluation of injector geometrical design features and propellant flow conditions on mixing and atomization. Increasing the free swirl angle of the liquid oxidizer had the greatest influence on increasing the mixing efficiency. The addition of gas assistance had the most significant effect on reducing oxidizer droplet size parameters and increasing droplet size distribution. Increasing the oxidizer injection velocity had the greatest influence for reducing oxidizer droplet size parameters and increasing size distribution for non-gas assisted flows. Single element and multi-element subscale hot fire testing are recommended to verify optimized designs before committing to the STME design.

Hulka, J.↗
DOE OSTI2022

Accelerated corrosion testing of cold spray coatings on 304L in chloride environments

Cold spray is an advanced metal manufacturing technique applied across many fields for a wide range of functions. Low heat input and compressive stresses induced into the substrate by the cold spray process makes it a promising choice for protective corrosion resistant coatings. One potential application for cold spray is as a protective coating against corrosion for spent nuclear fuel (SNF) interim dry storage canisters. As these canisters are currently stored at interim storage locations longer than originally intended, chloride induced stress corrosion cracking has been identified as a high priority knowledge gap, specifically with respect to prolonging or extending canister lifetimes ( Teague et al., 2019 ). The high deployability of cold spray, for which nozzles have been developed for application in constrained spaces, in conjunction with beneficial properties inherent to cold spray makes this a good candidate for a corrosion protection coating on SNF canisters. This work explores a pathway to rapidly down-select cold spray coatings for canisters by focusing on the corrosion properties. Specifically, this study examines the corrosion protection abilities of nickel and nickel-based alloy cold spray coatings on 304 L stainless steel in chloride rich environments through electrochemical scans and ferric chloride pitting tests (ASTM G48 Method A). It was shown that the porosity of the coating, the processing gas, material selection, and deformation in the substrate all impact the corrosion behavior of cold spray coatings and are areas where optimization could reduce potential materials degradation, enabling enhanced coatings development.

Karasz, Erin K.↗
NASA NTRS2006

Cold Flow Testing for Liquid Propellant Rocket Injector Scaling and Throttling

Scaling and throttling of combustion devices are important capabilities to demonstrate in development of liquid rocket engines for NASA's Space Exploration Mission. Scaling provides the ability to design new injectors and injection elements with predictable performance on the basis of test experience with existing injectors and elements, and could be a key aspect of future development programs. Throttling is the reduction of thrust with fixed designs and is a critical requirement in lunar and other planetary landing missions. A task in the Constellation University Institutes Program (CUIP) has been designed to evaluate spray characteristics when liquid propellant rocket engine injectors are scaled and throttled. The specific objectives of the present study are to characterize injection and primary atomization using cold flow simulations of the reacting sprays. These simulations can provide relevant information because the injection and primary atomization are believed to be the spray processes least affected by the propellant reaction. Cold flow studies also provide acceptable test conditions for a university environment. Three geometric scales - 1/4- scale, 1/2-scale, and full-scale - of two different injector element types - swirl coaxial and shear coaxial - will be designed, fabricated, and tested. A literature review is currently being conducted to revisit and compile the previous scaling documentation. Because it is simple to perform, throttling will also be examined in the present work by measuring primary atomization characteristics as the mass flow rate and pressure drop of the six injector element concepts are reduced, with corresponding changes in chamber backpressure. Simulants will include water and gaseous nitrogen, and an optically accessible chamber will be used for visual and laser-based diagnostics. The chamber will include curtain flow capability to repress recirculation, and additional gas injection to provide independent control of the backpressure. This paper provides a short review of the appropriate literature, as well as descriptions of plans for experimental hardware, test chamber instrumentation, diagnostics, and testing.

Kenny, Jeremy R.↗
DOE OSTI2025

Preparation and Qualification of Preproduction SSR2 Jacketed Cavities for PIP-II

The qualification of 325 MHz Single Spoke Resonators type 2 (SSR2) jacketed cavities to meet technical requirements represents a significant milestone in the development of the SSR2 cryomodules for the PIP-II Project at Fermilab. This poster reports the procedures and lessons learned in processing and preparing these cavities for horizontal cold testing prior to integration into a cavity string assembly, with a focus on addressing the field emission issues observed during the cold testing. A comprehensive root cause analysis identified critical fabrication, processing, and handling factors impacting field emission onset. New techniques were successfully developed and implemented to achieve field emission-free SSR2 cavities, and efforts were made to correlate radiation levels measured at the test stand with expected levels in the LINAC tunnel. Additionally, the evolution of field emission through assembly steps was thoroughly investigated, leading to a reassessment of design choices and enhancing our understanding of their effects on cavity performance.

Grassellino, L. [Fermilab]↗
NASA NTRS1975

Aerodynamic performance of a ceramic-coated core turbine vane tested with cold air in a two-dimensional cascade

The aerodynamic performance of a core turbine vane with a ceramic coating was investigated experimentally in a two-dimensional cascade of 10 vanes. The vane was first tested with a rough coating and then retested after the coating had been smoothed. The test fluid was atmospheric air. The cascade tests covered a range of pressure ratios corresponding to ideal exit critical velocity ratios of 0.6 to 0.95. The principal measurements were cross-channel surveys of exit total pressure, static pressure, and flow angle. The results presented include exit survey results and overall performance in terms of flow angle, weight flow, and kinetic energy loss. The performance of the ceramic-coated vanes is compared with the performance of an uncoated vane having a similar profile.

Stabe, R. G.↗
NASA NTRS1978

Effect of cooling-hole geometry on aerodynamic performance of a film-cooled turbine vane tested with cold air in a two-dimensional cascade

The effect of the orientation and cooling-hole size on turbine-vane aerodynamic losses was evaluated. The contribution of individual vane regions to the overall effect was also investigated. Test configurations were based upon a representative configuration having 45 spanwise rows of holes spaced about the entire vane profile. Nominal hole diameters of 0.0254 and 0.0356 cm and nominal hole orientations of 35 deg, 45 deg, and 55 deg from the local vane surface and 0 deg, 45 deg, and 90 deg from the main-stream flow direction were investigated. Flow conditions and aerodynamic losses were determined by vane-exit surveys of total pressure, static pressure, and flow angle.

Kline, J. F.↗
NASA NTRS1998

Computational Investigation of Helical Traveling Wave Tube Transverse RF Field Forces

In a previous study using a fully three-dimensional (3D) helical slow-wave circuit cold- test model it was found, contrary to classical helical circuit analyses, that transverse FF electric fields have significant amplitudes compared with the longitudinal component. The RF fields obtained using this helical cold-test model have been scaled to correspond to those of an actual TWT. At the output of the tube, RF field forces reach 61%, 26% and 132% for radial, azimuthal and longitudinal components, respectively, compared to radial space charge forces indicating the importance of considering them in the design of electron beam focusing.

Kory, Carol L.↗
NASA NTRS2007

Comparing the Robustness of High-Frequency Traveling-Wave Tube Slow-Wave Circuits

A three-dimensional electromagnetic field simulation software package was used to compute the cold-test parameters, phase velocity, on-axis interaction impedance, and attenuation, for several high-frequency traveling-wave tube slow-wave circuit geometries. This research effort determined the effects of variations in circuit dimensions on cold-test performance. The parameter variations were based on the tolerances of conventional micromachining techniques.

Chevalier, Christine T.↗
DOE OSTI2023

Prototype HB650 Cryomodule Heat Loads Simulations

During the design stages of the PIP-II cryomodules, many analytical calculations and FEA have been performed on simpler geometry in order to estimate the heat loads and also to optimize the design. To better analyze the cryomodule cold tests, simulations have been performed with MATLAB to determine the temperature of the main components during cool down and to determine the heat loads of the cryomodule. These simulations have been applied to the High Beta 650 MHz prototype cryomodule design and compared to the cold tests performed on it.

43 PARTICLE ACCELERATORS↗
NASA NTRS1997

Computer Simulation of Microwave Devices

The accurate simulation of cold-test results including dispersion, on-axis beam interaction impedance, and attenuation of a helix traveling-wave tube (TWT) slow-wave circuit using the three-dimensional code MAFIA (Maxwell's Equations Solved by the Finite Integration Algorithm) was demonstrated for the first time. Obtaining these results is a critical step in the design of TWT's. A well-established procedure to acquire these parameters is to actually build and test a model or a scale model of the circuit. However, this procedure is time-consuming and expensive, and it limits freedom to examine new variations to the basic circuit. These limitations make the need for computational methods crucial since they can lower costs, reduce tube development time, and lessen limitations on novel designs. Computer simulation has been used to accurately obtain cold-test parameters for several slow-wave circuits. Although the helix slow-wave circuit remains the mainstay of the TWT industry because of its exceptionally wide bandwidth, until recently it has been impossible to accurately analyze a helical TWT using its exact dimensions because of the complexity of its geometrical structure. A new computer modeling technique developed at the NASA Lewis Research Center overcomes these difficulties. The MAFIA three-dimensional mesh for a C-band helix slow-wave circuit is shown.

Kory, Carol L.↗
NASA NTRS1997

Computational Investigation of Experimental Interaction Impedance Obtained by Perturbation for Helical Traveling-Wave Tube Structures

Conventional methods used to measure the cold-test interaction impedance of helical slow-wave structures involve perturbing a helical circuit with a cylindrical dielectric rod placed on the central axis of the circuit. It has been shown that the difference in resonant frequency or axial phase shift between the perturbed and unperturbed circuits can be related to the interaction impedance. However, because of the complex configuration of the helical circuit, deriving this relationship involves-several approximations. With the advent of accurate three- dimensional helical circuit models, these standard approximations can be fully investigated. This paper addresses the most prominent approximations made in the analysis for measured interaction impedance by Lagerstrom and investigates their accuracy using the three-dimensional simulation code MAFIA. It is shown that a more accurate value of interaction impedance can be obtained by using three-dimensional computational methods rather than performing costly and time consuming experimental cold-test measurements.

Kory, Carol L.↗
NASA NTRS1998

Computational Investigation of Experimental Interaction Impedance Obtained by Perturbation for Helical Traveling Wave Tube Structures

Conventional methods used to measure the cold- test interaction impedance of helical slow-wave structures involve perturbing a helical circuit with a cylindrical dielectric rod placed on the central axis of the circuit It has been shown that the difference in resonant frequency or axial phase shift between the perturbed and unperturbed circuits can be related to the interaction impedance. However, because of the complex configuration of the helical circuit, deriving this relationship involves several approximations. With the advent of accurate three-dimensional (3-D) helical circuit models, these standard approximations can be fully Investigated. This paper addresses the most prominent approximations made in the analysis for measured interaction impedance by Lagerstrom and investigates their accuracy using the 3-D simulation code MAFIA. It is shown that a more accurate value of interaction impedance can be obtained by using 3-D computational methods rather than performing costly and time consuming experimental cold-test measurements.

Kory, Carol L.↗
NASA NTRS1998

Computational Investigation of Experimental Interaction Impedance Obtained by Perturbation for Helical Traveling-Wave Tube Structures

Conventional methods used to measure the cold-test interaction impedance of helical slow-wave structures involve perturbing a helical circuit with a cylindrical dielectric rod placed on the central axis of the circuit. It has been shown that the difference in resonant frequency or axial phase shift between the perturbed and unperturbed circuits can be related to the interaction impedance. However, because of the complex configuration of the helical circuit, deriving this relationship involves several approximations. With the advent of accurate three-dimensional (3-D) helical circuit models, these standard approximations can be fully investigated. This paper addresses the most prominent approximations made in the analysis for measured interaction impedance by Lagerstrom and investigates their accuracy using the 3-D simulation code MAFIA. It is shown that a more accurate value of interaction impedance can be obtained by using 3-D computational methods rather than performing costly and time consuming experimental cold-test measurements.

Kory, Carol L.↗